A coal cutter pick wear identification and efficient mining device and a control method thereof

Abstract

The application discloses a coal cutter pick wear identification and efficient mining device and a control method thereof. The device comprises a hydraulic rod, a pick auxiliary structure, a pick grabbing structure, a new pick library, a waste pick library and a hydraulic support. The pick auxiliary structure, the pick grabbing structure, the new pick library and the waste pick library are installed on the hydraulic support connected by the hydraulic rod. The application obtains the wear degree of each pick through the coal cutter pick wear identification and efficient mining device, identifies the wear, replaces the pick according to the wear state, or optimizes the cutting parameters according to the overall wear characteristics of the worn pick. A parameter optimization model is constructed according to the cutting parameters, the cutting depth and the pick wear degree characteristics, and the optimization of the cutting parameters and the cutting depth is realized by combining multi-parameter coupling optimization, so that the optimal drum rotating speed, the optimal traction speed and the optimal cutting depth under different wear degrees of the pick are obtained, and the efficient mining of the coal cutter is realized.

Description

Technical Field

[0001] This application relates to the field of coal mining technology, and in particular to a coal mining machine cutter tooth wear identification and high-efficiency mining device and its control method. Background Technology

[0002] Coal mining machines are crucial electromechanical equipment in coal mining, and their performance plays a decisive role in mining efficiency. The cutting section is the working component directly involved in coal mining, and its reliability and stability during operation affect the overall performance of the coal mining machine. During the cutting process, the cutting teeth need to be in direct contact with the coal and rock, resulting in significant wear. Drum speed, traction speed, and cutting depth are key operating parameters of the coal mining machine. Wear on the cutting teeth affects the mining efficiency. Therefore, how to promptly replace cutting teeth when missing teeth or severe wear is detected, accurately and quantitatively analyze the wear of the cutting teeth, and adaptively adjust drum speed, traction speed, and cutting depth in real time based on the degree of wear, thereby achieving efficient coal mining, are urgent problems to be solved.

[0003] Existing methods for analyzing the wear condition of cutting teeth involve using a main controller, vibration sensor, current sensor, infrared thermal imager, and display output structure to acquire vibration data, current data, and infrared images during the cutting process. The information is then displayed by the display output mechanism for the operator to judge. However, this method is greatly affected by external environmental factors, and the identification results are not accurate enough. Summary of the Invention

[0004] This application provides a coal mining machine cutting tooth wear identification and high-efficiency mining device and its control method. Based on the changes in the wear degree of multiple cutting teeth on the coal mining machine drum, the device achieves the optimal matching of comprehensive parameters such as the drum speed, traction speed and cutting depth. When a cutting tooth is detected to be severely worn or missing, the device can replace the cutting tooth in time, thereby achieving high-efficiency and high-quality operation of the coal mining machine.

[0005] To achieve the above objectives, this application provides a coal mining machine cutting tooth wear identification and high-efficiency mining device, comprising: a hydraulic rod, a cutting tooth auxiliary structure, a cutting tooth gripping structure, a new tooth magazine, a waste tooth magazine, and a hydraulic support; wherein the cutting tooth auxiliary structure, the cutting tooth gripping structure, the new tooth magazine, and the waste tooth magazine are mounted on the hydraulic support connected to the hydraulic rod.

[0006] Preferably, the toothed gripping structure includes: a gripping robotic arm and a gripping end;

[0007] The gripping robotic arm is composed of a robotic arm base, a large arm, and a small arm. The gripping robotic arm base is connected to one end of the large arm via a servo motor, the other end of the large arm is connected to one end of the small arm, and the other end of the small arm is fixedly connected to the gripping end structure.

[0008] The gripping end includes: an end support; a rotary motor is connected in the middle of the end support, and camera angle adjustment structures are connected to both ends of the rotary motor. A camera is installed on the camera angle adjustment structure. One side of the rotary motor is fixedly connected to the cutting tooth clamping block, and both sides of the cutting tooth clamping block are fixedly connected to one side of the servo motor. The output shaft of the other side of the servo motor is connected to the clamping link.

[0009] Preferably, the cutting tooth auxiliary structure includes: an auxiliary robotic arm and an auxiliary end effector; the auxiliary robotic arm has the same structure as the grasping robotic arm; the auxiliary end effector includes: an auxiliary end effector base; an auxiliary end effector motor is fixedly connected to the middle of the auxiliary end effector base, the two ends of the auxiliary end effector motor are connected to the camera angle adjustment structure, a camera is mounted on the camera angle adjustment structure, a servo motor is connected to one side of the auxiliary end effector motor, a lead screw is connected to one end of the servo motor, the lead screw passes through a slider, and the slider is fixedly connected to a retaining spring.

[0010] This application also provides a control method for a coal mining machine cutting tooth wear identification and high-efficiency mining device, used to control the above-mentioned device, including the following steps:

[0011] The coal mining machine's cutting tooth wear identification and high-efficiency mining device is used to perform a three-dimensional scan of the coal mining machine's drum to obtain a three-dimensional solid model of the coal mining machine's drum.

[0012] Based on the three-dimensional solid model, the wear degree of each cutting tooth is obtained and analyzed to obtain a single wear feature;

[0013] Based on the single wear characteristic, the cutting teeth are replaced or installed at the severely worn or missing tooth positions, resulting in a new distribution of new teeth and cutting teeth with different wear degrees on the coal mining machine drum;

[0014] Based on the new distribution of the new teeth and the cutting teeth with different wear degrees, the overall wear degree of the cutting teeth is obtained and analyzed to obtain the overall distribution characteristics of the worn cutting teeth;

[0015] Based on the overall distribution characteristics of the worn cutting teeth, the parameters of the drum speed, traction speed and cutting depth of the coal mining machine are optimized to achieve efficient mining by the coal mining machine.

[0016] Preferably, the parameter optimization method when the cutting teeth are in a state of slight wear or general wear includes:

[0017] Using the wear degree of the cutting teeth as the independent variable, the drum rotation speed, the traction speed and the cutting depth as optimization parameters, and the maximum mining efficiency of the coal mining machine as the optimization objective, an objective function is constructed.

[0018] The boundary conditions of the drum rotation speed, the traction speed, the cutting depth, and the cutting motor power and rotation speed of the coal mining machine are constrained to construct an optimization model for the cutting parameters of the coal mining machine.

[0019] The optimal drum speed, optimal traction speed, and optimal cutting depth are obtained by combining genetic algorithms.

[0020] Preferably, the constraint violation method is used to perform constraint processing on the truncation parameter optimization model.

[0021] Preferably, the method for obtaining the optimal drum rotation speed, the optimal traction speed, and the optimal cutting depth includes:

[0022] Initialize all the aforementioned optimization parameters;

[0023] Experiments were conducted based on the cutting parameter optimization model to set specific drum rotation speed, traction speed, and cutting depth, in order to obtain the optimal drum rotation speed, optimal traction speed, and optimal cutting depth.

[0024] Preferably, the experimental method includes:

[0025] Cutting experiments were conducted using the cutting teeth with different wear characteristics, as well as the pre-set drum speed, traction speed, and cutting depth. Multiple sets of experimental data were obtained, and the maximum mining efficiency under cutting experiments with cutting teeth of different wear degrees was calculated.

[0026] Based on the maximum mining efficiency, the drum rotation speed, the traction speed, and the cutting depth are continuously iterated using an optimization algorithm until the maximum mining efficiency is met, at which point the iteration stops.

[0027] The beneficial effects of this application are as follows:

[0028] A 3D solid model of the toothed drum is reconstructed using a 3D reconstruction method to obtain the wear degree of each cutting tooth. Wear identification is performed to understand the wear characteristics of the cutting teeth in real time. Cutting teeth are replaced based on their wear state, or cutting parameters are optimized based on the overall wear characteristics of the worn cutting teeth. A parameter optimization model is constructed based on the cutting parameters, cutting depth, and cutting tooth wear characteristics. Multi-parameter coupling optimization is used to optimize the cutting parameters and cutting depth, obtaining the optimal drum speed, optimal traction speed, and optimal cutting depth under different wear degrees of cutting teeth. This enables real-time adaptive adjustment of drum speed, traction speed, and cutting depth under different cutting tooth wear degrees, thereby achieving efficient mining by the coal mining machine. Using the coal mining machine cutting tooth wear identification and efficient mining device, not only can the toothed drum be scanned in 3D during the cutting process, but also fully autonomous cutting tooth replacement can be achieved, thereby reducing construction costs and improving the working efficiency of the coal mining machine. Attached Figure Description

[0029] To more clearly illustrate the technical solutions of this application, the drawings used in the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the structure of the coal mining machine cutter tooth wear identification and high-efficiency mining device of this application;

[0031] Figure 2 This is a schematic diagram of the gripping structure in the coal mining machine cutter tooth wear identification and high-efficiency mining device of this application;

[0032] Figure 3 This is a schematic diagram of the auxiliary structure of the cutting teeth in the coal mining machine cutting tooth wear identification and high-efficiency mining device of this application;

[0033] Figure 4 This is a flowchart illustrating the application of the coal mining machine cutter tooth wear identification and high-efficiency mining device in this application.

[0034] Figure 5 A flowchart illustrating the parameter optimization process for this application.

[0035] The components are as follows: 1. Hydraulic support; 2. Waste tooth storage; 3. New tooth storage; 4. Gripping robotic arm; 5. Gripping end effector; 6. Cutting tooth; 7. Auxiliary robotic arm; 8. Auxiliary end effector; 9. Roller; 10. Hydraulic rod; 11. Servo motor; 12. Baffle; 13. Clamping link; 14. Cutting tooth clamping block; 15. Camera; 16. Rotary motor; 17. End effector support; 18. Robotic arm base; 19. Servo motor; 20. Upper arm; 21. Lower arm; 22. Lead screw; 23. Slider; 24. Snap ring; 25. Auxiliary end effector motor; 26. Auxiliary end effector base. Detailed Implementation

[0036] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0037] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0038] Example 1

[0039] like Figure 1The diagram shows the structure of the coal mining machine cutting tooth wear identification and high-efficiency mining device of this application, including: hydraulic rod 10, cutting tooth auxiliary structure, cutting tooth gripping structure, waste tooth storage 2, new tooth storage 3 and hydraulic support 1; wherein, the cutting tooth auxiliary structure, cutting tooth gripping structure, waste tooth storage 2 and new tooth storage 3 are installed on the hydraulic support 1 connected to the hydraulic rod 10.

[0040] like Figure 2 The diagram shows the cutting tooth gripping structure of the aforementioned mining device, including a gripping robotic arm 4 and a gripping end cap 5. The gripping robotic arm 4 is composed of a robotic arm base 18, a large arm 20, and a small arm 21 connected together. The robotic arm base 18 is connected to one end of the large arm 20 via a servo motor 19. The other end of the large arm 20 is connected to one end of the small arm 21, and the other end of the small arm 21 is fixedly connected to the gripping end cap 5. The gripping end cap 5 includes an end support 17, with a rotary motor 16 connected in the middle. Camera angle adjustment structures are connected to both ends of the rotary motor 16, and cameras 15 are mounted on the camera angle adjustment structures. One side of the rotary motor 16 is fixedly connected to a cutting tooth clamping block 14, and both sides of the cutting tooth clamping block 14 are fixedly connected to one side of a servo motor 11. The output shaft of the other side of the servo motor 11 is connected to a clamping linkage 13.

[0041] like Figure 3 The auxiliary structure of the above-mentioned mining device includes an auxiliary robotic arm 7 and an auxiliary end effector 8. The auxiliary robotic arm 7 has the same structure as the gripping robotic arm 4 described above. The auxiliary end effector 8 includes an auxiliary end effector base 26, with an auxiliary end effector motor 25 fixedly connected in the middle of the auxiliary end effector base 26. Camera angle adjustment structures are connected to both ends of the auxiliary end effector motor 25, and cameras 15 are mounted on the camera angle adjustment structures. A servo motor 11 is connected to one side of the auxiliary end effector motor, and a lead screw 22 is connected to one end of the servo motor 11. The lead screw 22 passes through a slider 23, and the slider 23 is fixedly connected to a retaining ring 24.

[0042] Example 2

[0043] The following will describe in detail, with reference to this embodiment, how to use the coal mining machine cutting tooth wear identification and high-efficiency mining device of this application to perform quantitative identification of coal mining machine cutting tooth wear.

[0044] like Figure 4The diagram illustrates the application process for a coal mining machine cutter wear identification and high-efficiency mining device. A toothed drum with cutters of varying wear degrees is selected. A rotating motor 16 controls a camera to adjust its structure, and camera 15 captures images of the toothed drum from different angles, obtaining multiple frames of image data and acquiring point cloud data. The point cloud data undergoes preprocessing using methods such as filtering, denoising, data simplification, and data interpolation. The acquired depth images are then subjected to image enhancement processes including denoising and restoration. Point cloud data is calculated from the images to obtain the two-dimensional information and pixel values ​​of the preprocessed depth images, and the transformation relationship between the world coordinate system and the image coordinate system is calculated. Multiple frames of cutter images captured from different angles are analyzed to solve for the transformation parameters between frames. The point cloud data is then fused. A classic voxel-level reconstruction algorithm is used for surface generation, ultimately obtaining the cutter wear degree characteristics.

[0045] When the cutting teeth are severely worn, the tooth tips are almost completely worn away, resulting in a significant decrease in cutting performance, rendering them unsuitable for coal mining machines. When the cutting teeth are missing teeth, they are completely unsuitable for coal mining machines. Therefore, when the cutting teeth are severely worn or missing teeth, they need to be replaced using the device described in the above scheme to achieve efficient coal mining. The steps include:

[0046] The camera 15 is adjusted by driving the auxiliary end motor 25 to determine the specific position of the cutting tooth holder. The slider 23 is connected to the retaining spring 24 that fixes the cutting tooth. Then, the rotation direction of the lead screw 22 is controlled by the servo motor 11 to be counterclockwise, thereby driving the slider 23 to move and thus opening the retaining spring 24 that fixes the cutting tooth. Finally, the retaining spring 24 is removed by the auxiliary structure controlled by the auxiliary robotic arm 7. Afterward, the gripping robotic arm 4 is controlled by driving the servo motor 19. The camera 15 is used to determine the specific position of the cutting tooth head. Then, the angle of the gripping mechanism is adjusted by the gripping robotic arm 4 to ensure that the cutting tooth is fixed by the cutting tooth clamping block 14. Then, the clamping link 13 is controlled by rotating the servo motor 11 counterclockwise by a certain angle to "lock" the cutting tooth clamping block 14. Finally, the height of the gripping structure is controlled by the gripping robotic arm 4 to remove the cutting tooth and put it into the waste tooth magazine 2. To install a new cutting tooth, first take the new cutting tooth out of the new tooth magazine 3, and then install the new cutting tooth in the same way as the cutting tooth removal steps.

[0047] Combined with appendix Figure 5 The parameter optimization method for the cutting teeth when they are in a state of slight or general wear includes the following steps:

[0048] A target function is constructed with the wear degree of the cutting teeth as the independent variable, the drum speed, traction speed, and cutting depth as optimization parameters, and the maximum mining efficiency of the coal mining machine as the optimization objective.

[0049] By constraining the boundary conditions of the coal mining machine's drum speed, traction speed, cutting depth, cutting motor power and speed, an optimization model for the coal mining machine's cutting parameters is constructed.

[0050] Since there are many nonlinear constraints in the optimization of cut parameters, the constraint violation method is used for constraint handling.

[0051] The optimal drum speed, optimal traction speed, and optimal cutting depth are obtained by combining genetic algorithms.

[0052] Methods for obtaining optimal drum speed, optimal traction speed, and optimal cutting depth include:

[0053] Initialize all optimization parameters;

[0054] Based on the cutting parameter optimization model, specific drum speed, traction speed and cutting depth are set. Cutting experiments are conducted using cutting teeth with different wear characteristics and the set drum speed, traction speed and cutting depth. Multiple sets of experimental data are obtained, and the maximum mining efficiency under cutting experiments with cutting teeth of different wear degrees is calculated.

[0055] Based on the maximum mining efficiency mentioned above, the drum speed, traction speed and cutting depth are iterated continuously using a genetic algorithm until the maximum mining efficiency is met, thereby obtaining the optimal drum speed, optimal traction speed and optimal cutting depth.

[0056] The detailed steps for optimizing drum speed, traction speed, and cutting depth are as follows:

[0057] First, based on the update rules of the genetic algorithm, the experimental data obtained from the cutting experiments under different wear levels are divided into sample library A and sample library B. The genetic algorithm has two operators: a migration operator and an adjustment operator. Migration and adjustment operations are performed on sample library A and sample library B respectively to update the drum speed, traction speed, and cutting depth.

[0058] Let the total number of data in the two sample databases be NP, the total number of data in sample database A be NP1, the total number of data in sample database B be NP2 = NP - NP1, and the mobility be P;

[0059] In the migration operation performed on sample library A, the goal of the migration operator is to generate new drum speeds, traction speeds, and cutting depths from the drum speeds, traction speeds, and cutting depths in sample library A. Cutting parameters are updated according to the migration rules, where the migration rate is P = 5 / 12.

[0060] In the adjustment operation performed on sample library B, the goal of the adjustment operator is to sort the drum speed, traction speed and cutting depth in sample library B, and to adaptively update the cutting parameters according to the adjustment formula.

[0061] Based on the update rules of the migration and adjustment operations above, the drum speed, traction speed and cutting depth are continuously iterated and updated until the maximum mining efficiency is met, and the iteration stops, thereby obtaining the optimal drum speed, optimal traction speed and optimal cutting depth, and realizing the multi-parameter optimization of the coal mining machine.

[0062] The embodiments described above are merely preferred embodiments of this application and are not intended to limit the scope of this application. Any modifications and improvements made to the technical solutions of this application by those skilled in the art without departing from the spirit of this application shall fall within the protection scope defined by the claims of this application.

Claims

1. A device for identifying wear of coal mining machine cutting teeth and for efficient mining, comprising: The system includes a hydraulic rod, a cutting tooth auxiliary structure, a cutting tooth gripping structure, a new tooth magazine, a waste tooth magazine, and a hydraulic support; wherein the cutting tooth auxiliary structure, the cutting tooth gripping structure, the new tooth magazine, and the waste tooth magazine are mounted on the hydraulic support connected to the hydraulic rod. The cutting tooth gripping structure includes: a gripping robotic arm and a gripping end; The gripping robotic arm is composed of a robotic arm base, a large arm, and a small arm. The gripping robotic arm base is connected to one end of the large arm via a servo motor, the other end of the large arm is connected to one end of the small arm, and the other end of the small arm is fixedly connected to the gripping end structure. The gripping end includes: an end support; a rotary motor is connected in the middle of the end support, a camera angle adjustment structure is connected to both ends of the rotary motor, a camera is mounted on the camera angle adjustment structure, one side of the rotary motor is fixedly connected to the cutting tooth clamping block, both sides of the cutting tooth clamping block are fixedly connected to one side of the servo motor, and the output shaft of the other side of the servo motor is connected to the clamping link. The cutting tooth auxiliary structure includes: an auxiliary robotic arm and an auxiliary end effector; the auxiliary robotic arm has the same structure as the grasping robotic arm; the auxiliary end effector includes: an auxiliary end effector base; an auxiliary end effector motor is fixedly connected to the middle of the auxiliary end effector base, the two ends of the auxiliary end effector motor are connected to the camera angle adjustment structure, a camera is mounted on the camera angle adjustment structure, a servo motor is connected to one side of the auxiliary end effector motor, a lead screw is connected to one end of the servo motor, the lead screw passes through a slider, and the slider is fixedly connected to a retaining spring.

2. A control method for a coal mining machine cutter tooth wear identification and high-efficiency mining device, used to control the coal mining machine cutter tooth wear identification and high-efficiency mining device as described in claim 1, characterized in that, Includes the following steps: The coal mining machine's cutting tooth wear identification and high-efficiency mining device is used to perform a three-dimensional scan of the coal mining machine's drum to obtain a three-dimensional solid model of the coal mining machine's drum. Based on the three-dimensional solid model, the wear degree of each cutting tooth is obtained and analyzed to obtain a single wear feature; Based on the single wear characteristic, the cutting teeth are replaced or installed at the severely worn or missing tooth positions, resulting in a new distribution of new teeth and cutting teeth with different wear degrees on the coal mining machine drum; Based on the new distribution of the new teeth and the cutting teeth with different wear degrees, the overall wear degree of the cutting teeth is obtained and analyzed to obtain the overall distribution characteristics of the worn cutting teeth; Based on the overall distribution characteristics of the worn cutting teeth, the parameters of the drum speed, traction speed and cutting depth of the coal mining machine are optimized to achieve efficient mining by the coal mining machine.

3. The control method for coal mining machine cutter tooth wear identification and high-efficiency mining device according to claim 2, characterized in that, The parameter optimization method when the cutting tooth is in a state of slight wear or normal wear includes: Using the wear degree of the cutting teeth as the independent variable, the drum rotation speed, the traction speed and the cutting depth as optimization parameters, and the maximum mining efficiency of the coal mining machine as the optimization objective, an objective function is constructed. The boundary conditions of the drum rotation speed, the traction speed, the cutting depth, and the cutting motor power and rotation speed of the coal mining machine are constrained to construct an optimization model for the cutting parameters of the coal mining machine. The optimal drum speed, optimal traction speed, and optimal cutting depth are obtained by combining genetic algorithms.

4. The control method for coal mining machine cutter tooth wear identification and high-efficiency mining device according to claim 3, characterized in that, The constraint violation method is used to constrain the truncation parameter optimization model.

5. The control method for coal mining machine cutter tooth wear identification and high-efficiency mining device according to claim 3, characterized in that, The method for obtaining the optimal drum speed, the optimal traction speed, and the optimal cutting depth includes: Initialize all the aforementioned optimization parameters; Experiments were conducted based on the cutting parameter optimization model to set specific drum rotation speed, traction speed, and cutting depth, in order to obtain the optimal drum rotation speed, optimal traction speed, and optimal cutting depth.

6. The control method for coal mining machine cutter tooth wear identification and high-efficiency mining device according to claim 5, characterized in that, The experimental methods include: Cutting experiments were conducted using the cutting teeth with different wear characteristics, as well as the pre-set drum speed, traction speed, and cutting depth. Multiple sets of experimental data were obtained, and the maximum mining efficiency under cutting experiments with cutting teeth of different wear degrees was calculated. Based on the maximum mining efficiency, the drum rotation speed, the traction speed, and the cutting depth are continuously iterated using an optimization algorithm until the maximum mining efficiency is met, at which point the iteration stops.

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