A dual-mode roadway support control system and method based on PLC

Abstract

The disclosure provides a PLC-based dual-mode roadway support control system and method. The control device of the system includes a main control cabinet and a remote control box. The remote control box is used to send a mode switching instruction to the main control cabinet. The mode switching instruction includes a manual mode switching instruction and an automatic mode switching instruction. The main control cabinet is used to generate a first control signal when receiving the automatic mode switching instruction and to generate a second control signal by acquiring a hydraulic cylinder adjustment instruction sent by the remote control box when receiving the manual mode switching instruction. The hydraulic device includes a hydraulic valve group. The hydraulic valve group is used to control the installation device based on the first control signal or the second control signal of the control device to achieve the installation and disassembly of the shed frame. The installation device includes two single-side installation devices arranged in mirror symmetry. Each single-side installation device includes a hydraulic cylinder unit for controlling the shed frame and the installation arm. According to the system of the disclosure, remote shed support for the roadway can be achieved, thereby replacing manual support to protect the safety and health of coal mine workers.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the technical field of roadway support, in particular to a dual-mode roadway support control system and method based on PLC. BACKGROUND

[0002] At present, coal mines in China are mainly underground mining. In the process of underground mining, a large number of roadways need to be excavated underground, and the use of roadway support to maintain the smoothness of the roadway and the stability of the surrounding rock is of great significance to the construction and production of coal mines.

[0003] The shed support is one of the common methods of roadway support in the process of coal mining. At present, the support method mainly adopts manual support, which is a great test to the health and safety of the workers. In addition, the existing related technology is difficult to realize the automation of roadway support control, and is difficult to adapt to the complex and uneven internal environment of the roadway, and is more difficult to realize unmanned and automation. SUMMARY

[0004] The present disclosure aims to at least partially solve one of the technical problems in the related art.

[0005] To this end, the present disclosure provides a dual-mode roadway support control system and method based on PLC, the main purpose of which is to realize remote shed support of the roadway, thereby replacing manual support to protect the safety and health of coal mine workers.

[0006] According to a first aspect of the present disclosure, a dual-mode roadway support control system based on PLC is provided, the dual-mode including a manual mode and an automatic mode, the support control system comprising a control device, a hydraulic device and a mounting device, the control device being connected with the mounting device via the hydraulic device;

[0007] The control device comprises a main control cabinet and a remote control box, the main control cabinet and the remote control box being connected, the remote control box being configured to send a mode switching instruction to the main control cabinet, the mode switching instruction comprising a manual mode switching instruction and an automatic mode switching instruction, the main control cabinet being configured to generate a first control signal based on an automatic installation instruction when the automatic mode switching instruction is received, and to generate a second control signal based on a hydraulic cylinder adjustment instruction sent by the remote control box when the manual mode switching instruction is received;

[0008] The hydraulic device comprises a hydraulic valve group, the hydraulic valve group being configured to control the mounting device based on the first control signal or the second control signal of the control device to realize the installation and disassembly of the shed frame;

[0009] The mounting device comprises two single-side mounting devices arranged in mirror symmetry, each single-side mounting device comprising a hydraulic cylinder unit for controlling the shed frame and the mounting arm.

[0010] In one embodiment of the present disclosure, the remote control box comprises a data acquisition card module and a switch element module, one end of the data acquisition card module is connected with the switch element module, the other end of the data acquisition card module is connected with the main control cabinet, the switch element module comprises a first switch element unit and a second switch element unit, the first switch element unit is used for generating a mode switching instruction, the second switch element unit is used for generating a cylinder adjustment instruction, and the data acquisition card module is used for sending the mode switching instruction and the cylinder adjustment instruction to the main control cabinet.

[0011] In one embodiment of the present disclosure, the main control cabinet comprises a PLC main control module and an intermediate relay module, one end of the PLC main control module is connected with the data acquisition card module, the other end of the PLC main control module is connected with the hydraulic device via the intermediate relay module; the PLC main control module is used for controlling the on-off of the intermediate relay module based on an automatic installation instruction according to a preset installation process to make the intermediate relay module generate a first control signal when the automatic mode switching instruction is received, and is also used for controlling the on-off of the intermediate relay module based on a cylinder adjustment instruction to make the intermediate relay module generate a second control signal when the manual mode switching instruction is received.

[0012] In one embodiment of the present disclosure, the cylinder unit comprises a plurality of oil cylinders, and the number of the oil cylinders is equal to the number of the hydraulic valve groups, and each oil cylinder is controlled by one hydraulic valve group.

[0013] In one embodiment of the present disclosure, the cylinder unit comprises a first cylinder unit, a second cylinder unit and a third cylinder unit, the first cylinder unit is used for controlling the movement of the shed frame, the second cylinder unit is used for locking the shed frame, and the third cylinder unit is used for controlling the extension of the installation arm.

[0014] In one embodiment of the present disclosure, the switch element module further comprises an emergency stop button, the emergency stop button is used for generating an emergency stop signal and a first recovery signal, the data acquisition card module is further used for sending the emergency stop signal or the first recovery signal to the main control cabinet, and the main control cabinet controls the double-mode roadway support control system to stop running or resume running based on the emergency stop signal or the first recovery signal.

[0015] In one embodiment of the present disclosure, the switch element module further comprises a timeout recovery button, the timeout recovery button is used for generating a second recovery signal when a fault is removed, the data acquisition card module is further used for sending the second recovery signal to the main control cabinet, and the main control cabinet controls the double-mode roadway support control system to resume running based on the second recovery signal.

[0016] In one embodiment of this disclosure, the remote control box further includes multiple indicator lights, which are connected to the data acquisition card module. The indicator lights illuminate and turn off based on the status signal output by the data acquisition card module to indicate different states of the dual-mode roadway support control system.

[0017] According to a second aspect of this disclosure, a PLC-based dual-mode roadway support control method is provided, employing the PLC-based dual-mode roadway support control system described in the first aspect embodiment, comprising:

[0018] Obtain mode switching instructions, including instructions to switch to manual mode and instructions to switch to automatic mode;

[0019] If an automatic mode switching command is received, the main control cabinet generates a first control signal based on the automatic installation command. If the manual mode switching command is received, the main control cabinet obtains the cylinder adjustment command sent by the remote control box to generate a second control signal.

[0020] Based on the first control signal or the second control signal, the hydraulic cylinder unit of the installation device is controlled by a hydraulic device to realize the installation and dismantling of the scaffold.

[0021] In one embodiment of this disclosure, the main control cabinet includes a PLC main control module and an intermediate relay module. The step of generating a first control signal based on an automatic installation instruction when an automatic mode switching instruction is received includes: when the automatic mode switching instruction is received, the PLC main control module controls the on / off state of the intermediate relay module according to a preset installation process based on the automatic installation instruction, so that the intermediate relay module generates the first control signal.

[0022] In one or more embodiments of this disclosure, the dual-mode includes a manual mode and an automatic mode. The support control system includes a control device, a hydraulic device, and an installation device. The control device is connected to the installation device via the hydraulic device. The control device includes a main control cabinet and a remote control box, which are connected. The remote control box is used to send mode switching commands to the main control cabinet. The mode switching commands include a manual mode switching command and an automatic mode switching command. When the automatic mode switching command is received, the main control cabinet is used to generate a first control signal based on an automatic installation command. When the manual mode switching command is received, the main control cabinet acquires a cylinder adjustment command sent by the remote control box to generate a second control signal. The hydraulic device includes a hydraulic valve group, which is used to control the installation device based on the first or second control signal from the control device to realize the installation and dismantling of the scaffold. The installation device includes two single-sided installation devices arranged in a mirror-symmetrical manner. Each single-sided installation device includes a cylinder unit for controlling the scaffold and the installation arm. In this scenario, by comprehensively utilizing control devices, hydraulic devices, and installation devices, and remotely controlling the hydraulic and installation devices through the control devices, the installation and dismantling of the support frame can be achieved. This avoids the need for manual support during the installation and dismantling of the support frame, enabling remote support of the roadway and thus protecting the safety and health of coal miners.

[0023] Additional aspects and advantages of this disclosure will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this disclosure. Attached Figure Description

[0024] The above and / or additional aspects and advantages of this disclosure will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, in which:

[0025] Figure 1 This diagram illustrates a block diagram of a PLC-based dual-mode roadway support control system provided in an embodiment of this disclosure.

[0026] Figure 2 This diagram shows the internal components of the control device provided in an embodiment of the present disclosure;

[0027] Figure 3(a) shows a three-dimensional structural diagram of the remote control box provided in the embodiment of this disclosure;

[0028] Figure 3(b) shows a front view of the remote control box provided in an embodiment of this disclosure;

[0029] Figure 4 This diagram illustrates the structure of a single-sided mounting device provided in an embodiment of the present disclosure.

[0030] Figure 5(a) shows a schematic diagram of the main control logic flow provided in an embodiment of this disclosure;

[0031] Figure 5(b) shows a schematic diagram of the manual control logic flow provided in an embodiment of this disclosure;

[0032] Figure 5(c) shows a schematic diagram of the automatic control logic flow provided in an embodiment of this disclosure;

[0033] Figure 5(d) shows a schematic diagram of the emergency stop logic flow provided in an embodiment of this disclosure;

[0034] Figure 5(e) shows a schematic diagram of the timeout logic flow provided in an embodiment of this disclosure;

[0035] Figure 6 The flowchart illustrates a PLC-based dual-mode roadway support control method provided in an embodiment of this disclosure. Detailed Implementation

[0036] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with those of this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of the embodiments of this disclosure as detailed in the appended claims.

[0037] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0038] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this disclosure, "a plurality of" means at least two, such as two, three, etc., unless otherwise expressly and specifically defined. It should also be understood that the term "and / or" as used in this disclosure refers to and includes any or all possible combinations of one or more associated listed items.

[0039] Embodiments of this disclosure are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this disclosure, and should not be construed as limiting this disclosure.

[0040] This disclosure provides a PLC-based dual-mode roadway support control system and method, primarily aimed at achieving remote canopy support for roadways, thereby replacing manual support to protect the safety and health of coal miners. The dual modes involved in this disclosure include a manual mode and an automatic mode. In automatic mode, the support control system and method of this disclosure can automatically achieve remote canopy support for the roadway. In manual mode, the roadway support control system and method of this disclosure are used to achieve remote canopy support for the roadway via remote control.

[0041] In the first embodiment, Figure 1 This diagram illustrates a PLC-based dual-mode roadway support control system according to an embodiment of the present disclosure. Figure 1 As shown, the PLC-based dual-mode roadway support control system includes a control device, a hydraulic device, and an installation device. The control device is connected to the installation device via the hydraulic device.

[0042] In this embodiment, the control device includes a main control cabinet and a remote control box, which are connected together.

[0043] In this embodiment, the remote control box is used to send mode switching instructions to the main control cabinet. The mode switching instructions include manual mode switching instructions and automatic mode switching instructions. When the automatic mode switching instruction is received, the main control cabinet is used to generate a first control signal based on the automatic installation instruction. When the manual mode switching instruction is received, the main control cabinet obtains the cylinder adjustment instruction sent by the remote control box to generate a second control signal.

[0044] Specifically, Figure 2 Figure 3(a) shows a three-dimensional structural diagram of the remote control box provided in an embodiment of the present disclosure. Figure 3(b) shows a front view of the remote control box provided in an embodiment of the present disclosure. Figure 2 As shown, the control device includes a main control cabinet and a remote control box. The main control cabinet and the remote control box are communicatively connected.

[0045] In this embodiment, the remote control box includes a data acquisition card module and a switching element module. One end of the data acquisition card module is connected to the switching element module, and the other end is connected to the main control cabinet. The data acquisition card module may include multiple TD4055 data acquisition cards (see...). Figure 2For example, there are 5 TD4055 data acquisition cards. Each TD4055 data acquisition card has 8 input and 8 output channels, uses Modbus RTU mode for data transmission, and employs the RS485 communication protocol to transmit data with the PLC main control module of the main control cabinet (described later).

[0046] The switching element module includes a first switching element unit and a second switching element unit. The first switching element unit is used to generate mode switching commands, and the second switching element unit is used to generate hydraulic cylinder adjustment commands. The data acquisition card module is used to send the mode switching commands and hydraulic cylinder adjustment commands from the switching element module to the main control cabinet.

[0047] As shown in Figures 3(a) and 3(b), the switching element module can be composed of multiple knobs and buttons on the panel of the remote control box. The panel includes 30 buttons (buttons 1 to 30), 2 knobs (knobs 31 and 32), and 1 emergency stop button (button 33). Buttons 1 to 24 form the second switching element unit, used to generate cylinder adjustment commands in manual mode to directly control the forward / reverse movement of the 12 cylinders on both sides. Knob 32 forms the first switching element unit, used to generate mode switching commands to switch between automatic and manual modes. Button 25 is used to generate automatic installation commands in automatic mode to achieve automatic cylinder installation.

[0048] In this embodiment, the switching element module also includes an emergency stop button, which is used to generate an emergency stop signal and a first recovery signal. The data acquisition card module is also used to send the emergency stop signal or the first recovery signal to the main control cabinet. The main control cabinet controls the dual-mode roadway support control system to stop or resume operation based on the emergency stop signal or the first recovery signal. As shown in Figures 3(a) and 3(b), the emergency stop button 33 is used to realize the emergency stop of the hydraulic device.

[0049] In this embodiment, the switching element module also includes a timeout recovery button, which is used to generate a second recovery signal when the fault is cleared. The data acquisition card module is also used to send the second recovery signal to the main control cabinet, and the main control cabinet controls the dual-mode roadway support control system to resume operation based on the second recovery signal. As shown in Figures 3(a) and 3(b), button 30 is used to realize the clearing and recovery of the timeout fault.

[0050] In this embodiment, the switching element module also includes a knob for controlling the opening and closing of the hydraulic device. As shown in Figures 3(a) and 3(b), the knob 31 controls the opening and closing of the hydraulic device.

[0051] In this embodiment, the data acquisition card module in the remote control box acquires signals from the buttons or knobs on the remote control box panel (such as mode switching commands and cylinder adjustment commands), and transmits the acquired signals to the PLC main control module, thereby realizing remote control of the intermediate relay module.

[0052] In this embodiment, as Figure 2 As shown, the remote control box also includes indicator lights, which are connected to the data acquisition card module. The indicator lights illuminate and deactivate based on the status signals output by the data acquisition card module to indicate different states of the dual-mode roadway support control system. The status signals output by the data acquisition card module come from the PLC main control module. As shown in Figures 3(a) and 3(b), the remote control box includes two indicator lights, namely indicator light 34 and indicator light 35. Indicator light 34 is used to indicate whether the system is in working condition, and indicator light 35 is used to indicate whether the system has a fault.

[0053] In this embodiment, the main control cabinet includes a PLC main control module and an intermediate relay module. One end of the PLC main control module is connected to the data acquisition card module, and the other end of the PLC main control module is connected to the hydraulic device via the intermediate relay module. The PLC main control module is used to control the on / off state of the intermediate relay module according to the automatic installation command and the preset installation process when it receives the command to switch to automatic mode, so that the intermediate relay module generates a first control signal. It is also used to control the on / off state of the intermediate relay module according to the cylinder adjustment command when it receives the command to switch to manual mode, so that the intermediate relay module generates a second control signal.

[0054] In this embodiment, the PLC main control module can adopt the Siemens ET200SP distributed I / O system, which includes a data communication unit, a data input (DI) unit, and a data output (DQ) unit.

[0055] In this embodiment, the intermediate relay module may include multiple intermediate relays. Each intermediate relay is switched on and off based on the control of the PLC main control module, thereby controlling the movement of the motor and the hydraulic cylinder. For example, the number of intermediate relays may be 28.

[0056] In this embodiment, the main control cabinet may further include a power supply. The power supply can provide electrical energy to the various modules in the main control cabinet.

[0057] In this embodiment, the main control cabinet may also include multiple AC contactors. The AC contactors utilize electromagnetic force combined with spring force to achieve the connection and disconnection of contacts. For example, the number of AC contactors may be three.

[0058] In this embodiment, the main control cabinet may further include an AC frequency converter. The AC frequency converter is used to control the rotation speed of the motor of the hydraulic device 12, making the rotation speed adjustable within a certain range. For example, there are two AC frequency converters.

[0059] In this embodiment, the hydraulic device includes a hydraulic valve group, which is used to control the installation device based on a first control signal or a second control signal from the control device to realize the installation and dismantling of the scaffold.

[0060] Specifically, the hydraulic valve group controls the installation device based on a first control signal from the control device to achieve the installation of the scaffolding, and the hydraulic valve group controls the installation device based on a second control signal from the control device to achieve the installation and dismantling of the scaffolding. The number of hydraulic valve groups is equal to the number of hydraulic cylinders, and each hydraulic cylinder is controlled by one hydraulic valve group. Each hydraulic valve group controls the movement of a corresponding hydraulic cylinder, etc.

[0061] The hydraulic valve group consists of a pressure sensor, a hydraulic lock or balance valve, and a three-position four-way directional valve. Each cylinder is controlled by a hydraulic valve group in the hydraulic device. The three-position four-way solenoid valve controls the cylinder to have three states: forward, backward, and pressure holding. It also controls some cylinders to have a floating state.

[0062] The hydraulic system also includes a hydraulic power unit. The hydraulic power unit includes a tandem pump and a relief valve. The hydraulic system is supplied with oil through the tandem pump to ensure that the oil supply is basically the same on both sides. The relief valve can stabilize the pressure and switch states to reduce energy consumption when the hydraulic system is not working.

[0063] The hydraulic system also includes an electric motor. The motor is connected to the tandem pump and is used to control the operating status of the tandem pump.

[0064] In this embodiment, the installation device includes two single-sided installation devices arranged in a mirror-symmetrical manner, each single-sided installation device including a hydraulic cylinder unit for controlling the scaffold and the installation arm. The hydraulic cylinder unit includes multiple hydraulic cylinders.

[0065] Specifically, the hydraulic cylinder unit includes a first hydraulic cylinder unit, a second hydraulic cylinder unit, and a third hydraulic cylinder unit.

[0066] The first hydraulic cylinder unit is used to control the movement of the scaffolding. The movement directions include horizontal and vertical.

[0067] The second hydraulic cylinder unit is used to lock the scaffolding. Before controlling the movement of the scaffolding, the second hydraulic cylinder unit locks it to prevent problems such as scaffolding detachment during movement. After the scaffolding is moved, the second hydraulic cylinder unit unlocks it, allowing the installation device to detach from the scaffolding.

[0068] The third hydraulic cylinder unit is used to control the extension of the mounting arm. The mounting arm is connected to the scaffold. When the third hydraulic cylinder unit is working, it can control the mounting arm to extend up and down, thereby moving the scaffold. When the third hydraulic cylinder unit is not working, neither the mounting arm nor the scaffold can move.

[0069] Figure 4 A schematic diagram of the structure of the single-sided mounting device provided in an embodiment of this disclosure is shown.

[0070] In this embodiment, as Figure 4 As shown, the installation device for tunnel canopy support consists of a left-side installation device and a right-side installation device that are completely mirror-symmetrical. Taking the left-side installation device as an example, as... Figure 4 As shown, the mounting device on the left includes six hydraulic cylinders. Cylinder E is the fourth hydraulic cylinder.

[0071] Hydraulic cylinders A, B, C, and D form the first hydraulic cylinder unit. Cylinders A and B are responsible for horizontal extension and retraction, thus controlling the horizontal movement of the scaffold. Cylinders C and D are responsible for vertical extension and retraction, thus controlling the vertical movement of the scaffold. Hydraulic cylinder E is the second hydraulic cylinder unit. Cylinder E is responsible for extending the support claws to grip the scaffold. Before controlling the movement of the scaffold, cylinder E locks the scaffold. After the movement is complete, cylinder E unlocks the scaffold, allowing the installation device to detach from the scaffold. Hydraulic cylinder F is the third hydraulic cylinder unit. When cylinder F is working, it controls the vertical extension and retraction of the installation arm, thereby moving the scaffold. When cylinder F is not working, neither the installation arm nor the scaffold can move. Thus, the installation or disassembly of the scaffold is accomplished by manipulating these six hydraulic cylinders. During installation, the six cylinders have three states: forward, backward, and pressure holding. Cylinders B and C additionally provide a floating state.

[0072] Figure 5(a) shows a schematic diagram of the main control logic flow provided in an embodiment of the present disclosure; Figure 5(b) shows a schematic diagram of the manual control logic flow provided in an embodiment of the present disclosure; Figure 5(c) shows a schematic diagram of the automatic control logic flow provided in an embodiment of the present disclosure; Figure 5(d) shows a schematic diagram of the emergency stop logic flow provided in an embodiment of the present disclosure; Figure 5(e) shows a schematic diagram of the timeout logic flow provided in an embodiment of the present disclosure.

[0073] The logic flow for remote support using the PLC-based dual-mode roadway support control system disclosed herein can include main control logic, manual control logic, automatic control logic, emergency stop logic, and timeout logic. The specific processes of each logic flow are as follows:

[0074] (1) As shown in Figure 5(a), the main control logic includes: powering on and initializing the entire control system (including powering on the PLC and performing Modbus communication), turning the knob 32 to adjust the control mode to automatic or manual mode to realize signal conversion, and switching to the corresponding automatic / manual control state. At this time, the remote control box generates a manual mode switching command or an automatic mode switching command. The main control cabinet performs manual / automatic control based on the manual mode command or the automatic mode switching command. During the control process, it is determined whether the oil cylinder has reached the designated position. If so, the installation device is removed from the scaffold and the installation is completed. If it has not reached the designated position, the control continues.

[0075] (2) As shown in Figure 5(b), the manual control logic includes: powering on and initializing the entire control system (including powering on the PLC and performing Modbus communication), turning knob 32 to switch the control mode to manual mode, at which time the remote control box generates a command to switch to manual mode; and controlling the hydraulic cylinders to move forward / backward by pressing the corresponding buttons (such as buttons 1-24). Specifically, hydraulic cylinder adjustment commands can be generated by manually controlling the relevant buttons on the remote control box. The hydraulic cylinder adjustment commands are transmitted to the main control cabinet via the data acquisition card module. The main control cabinet controls the hydraulic cylinders based on the hydraulic cylinder adjustment commands to control each hydraulic cylinder to move forward or backward. When the control button of the corresponding hydraulic cylinder is pressed, the hydraulic cylinder performs the corresponding movement. The movement sequence of the hydraulic cylinders is consistent with that in the automatic mode. The disassembly process is completely reversed from the installation process. During the control process, emergency stop fault detection is also performed to determine whether all hydraulic cylinders have reached the specified position. If so, the installation is completed; otherwise, the hydraulic cylinders are continued to be operated by the buttons. Thus, in manual mode, the installation and disassembly of the scaffolding can be achieved through several buttons on the remote control box.

[0076] (3) As shown in Figure 5(c), with Figure 4 Taking the six hydraulic cylinders shown as an example, the automatic control logic includes: powering on and initializing the entire control system (including powering on the PLC and performing Modbus communication), turning knob 32 to switch the control mode to automatic mode to achieve signal conversion and switch to automatic control state. At this time, the remote control box generates a command to switch to automatic mode, and at the same time adjusts the speed control valve of the hydraulic valve group to the corresponding position. Then, press button 25, and the remote control box generates an automatic installation command to start installation.

[0077] When the overflow valve is switched to the working state, the main control cabinet, upon receiving the command to switch to automatic mode, controls the on / off state of the intermediate relay module according to the preset installation process based on the automatic installation command, thereby controlling the hydraulic valve group to ultimately control each cylinder.

[0078] The preset installation process includes: 1) Control cylinder A to move forward, determine if cylinder A has reached the designated position. If so, cylinder A maintains pressure, and cylinder B moves forward; otherwise, continue controlling cylinder A to move forward. Specifically, adjust the solenoid valve controlling cylinder A to the forward position, move the installation device to the left to the location of the scaffold, control cylinder A to the designated position, and cylinder A maintains pressure; 2) Determine if cylinder B has reached the designated position. If cylinder B floats, cylinder E moves forward; otherwise, continue controlling cylinder B to move forward. Specifically, adjust the solenoid valve controlling cylinder B to the forward position, control cylinder B to the designated position, and the installation device moves the scaffold to the support planes on both sides of the roadway, and cylinder B floats; 3) Determine if cylinder E has reached the designated position. If cylinder E maintains pressure, cylinder F moves forward; otherwise, continue controlling cylinder E to move forward. Specifically, the solenoid valve controlling the movement of cylinder E is set to the forward position, the robotic gripper opens and supports the scaffold mounting hole, and cylinder E maintains pressure; 4) Determine if cylinder F has reached the designated position. If so, cylinder F maintains pressure; otherwise, continue controlling cylinder F to move forward. Specifically, the solenoid valve controls cylinder F to move to the designated position, closes the scaffold's self-locking mechanism to allow the scaffold to open up and down, and cylinder F maintains pressure; 5) C floats, and cylinder D moves forward. Determine if cylinder D has reached the designated position. If so, the installation device is removed from the scaffold, and the installation is complete; otherwise, continue controlling cylinder C to float and cylinder D to move forward. Specifically, the solenoid valve controls cylinder C to float, the solenoid valve controlling cylinder D is set to the forward position, cylinder D moves to the designated position, ensuring full contact between the top of the scaffold and the top of the tunnel, and cylinder D maintains pressure.

[0079] (4) As shown in Figure 5(d), the emergency stop logic includes: when an emergency is observed in automatic / manual mode (i.e., a fault is observed), pressing the emergency stop knob will stop all cylinders from moving, which can quickly and protectively stop the moving cylinders. When the emergency is resolved (i.e., the fault is cleared), rotating the emergency stop knob will restore the system to normal. The specific process is as follows: when an emergency occurs, pressing the emergency stop button 33 will generate an emergency stop signal in the remote control box. The main control cabinet will control all cylinders to stop moving and switch to the pressure holding state based on the emergency stop signal. The fault indicator light will illuminate. When the emergency is resolved, rotating the emergency stop knob 33 will reset it. The remote control box will generate a first recovery signal. The main control cabinet will restore the system to normal based on the first recovery signal. During the fault inspection process, the cylinder working mode does not need to be switched.

[0080] (5) As shown in Figure 5(e), the timeout logic includes: when the cylinder movement timeout occurs in automatic mode, the timeout fault position is set to 1. At this time, all cylinders are controlled to stop moving. After the fault is cleared, the system switches to manual mode to reset the cylinders. Then, the system switches back to automatic mode and initializes. Then, the system automatically controls the cylinders to start moving again. The specific process is that when the cylinder movement time exceeds the preset value but does not reach the specified position, the system performs a protective stop operation on all moving cylinders, that is, all cylinders stop moving and switch to the pressure holding state. The fault indicator light is on. At this time, the control mode needs to be adjusted to manual mode by rotating knob 32. At the same time, the fault cause of the entire system is detected, and the cylinder reset is manually adjusted. After the fault is cleared, the protective stop of the cylinders is released by manually pressing button 30.

[0081] The PLC-based dual-mode roadway support control system disclosed herein has several advantages, namely: it enables remote roadway support, improving support efficiency and stability; the remote control cabinet can be placed far from the working face, ensuring miners' safety and health; it has both automatic and manual support modes, improving support efficiency; the manual mode allows for fine-tuning of the support position and timely response to malfunctions, enhancing the stability of the control system; it incorporates timeout and emergency stop controls, effectively mitigating most potential roadway support system failures and improving overall system stability; the control method has a simple principle and clear logic; the entire device occupies a small area, making it suitable for complex and harsh mining environments in roadways.

[0082] In this embodiment of the PLC-based dual-mode roadway support control system, the dual modes include manual mode and automatic mode. The support control system includes a control device, a hydraulic device, and an installation device. The control device is connected to the installation device via the hydraulic device. The control device includes a main control cabinet and a remote control box, which are connected. The remote control box is used to send mode switching commands to the main control cabinet. The mode switching commands include a command to switch to manual mode and a command to switch to automatic mode. When the main control cabinet receives the command to switch to automatic mode, it generates a first control signal based on an automatic installation command. When it receives the command to switch to manual mode, it acquires a cylinder adjustment command sent by the remote control box to generate a second control signal. The hydraulic device includes a hydraulic valve group, which is used to control the installation device based on the first or second control signal from the control device to realize the installation and dismantling of the scaffold. The installation device includes two single-sided installation devices arranged in a mirror-symmetrical manner. Each single-sided installation device includes a cylinder unit for controlling the scaffold and the installation arm. In this scenario, the control device, hydraulic device, and installation device are integrated. The control device remotely controls the hydraulic device and installation device to achieve the installation and dismantling of the support frame, avoiding manual support methods. This enables remote support of the roadway, thus protecting the safety and health of coal miners. The control system disclosed herein is applicable to the intelligent transformation of coal mining equipment. Signals are transmitted to a data acquisition card via buttons on the remote control box. The data acquisition card exchanges data with a PLC via the RS485 communication protocol. The PLC controls the corresponding relays to control the hydraulic device for roadway support, thereby controlling the cylinders. The cylinders move the support frame to the designated position, ultimately completing the support process. The control process has both manual and automatic modes. The manual mode can be used for support frame installation and dismantling, while the automatic mode enables unmanned remote installation of the support frame. It also adds emergency stop and timeout control for the cylinders. Compared to manual support, this control method is safer and has better adaptability.

[0083] The following are embodiments of the method disclosed herein. For details not disclosed in the embodiments of the method disclosed herein, please refer to the system embodiments of the method disclosed herein. The embodiments of the method disclosed herein propose a PLC-based dual-mode roadway support control method. This PLC-based dual-mode roadway support control method uses the PLC-based dual-mode roadway support control system described in the above system embodiments for remote scaffold support.

[0084] Figure 6 A flowchart illustrating a PLC-based dual-mode roadway support control method provided in an embodiment of this disclosure is shown. Figure 6 As shown, the PLC-based dual-mode roadway support control method includes:

[0085] Step S11: Obtain mode switching instructions, which include instructions to switch to manual mode and instructions to switch to automatic mode.

[0086] Step S12: If an automatic mode switching command is received, the main control cabinet generates a first control signal based on the automatic installation command; if a manual mode switching command is received, the main control cabinet obtains the cylinder adjustment command sent by the remote control box to generate a second control signal.

[0087] Step S13: Based on the first control signal or the second control signal, the hydraulic cylinder unit of the installation device is controlled by the hydraulic device to realize the installation and disassembly of the scaffold.

[0088] In step S11, the mode switching command can be generated by the remote control box. For details, please refer to the relevant description in the above system embodiment, which will not be repeated here.

[0089] In step S12, the main control cabinet includes a PLC main control module and an intermediate relay module. If an automatic mode activation command is received, the main control cabinet generates a first control signal based on the automatic installation command. This includes: upon receiving the automatic mode activation command, the PLC main control module controls the on / off state of the intermediate relay module according to a preset installation procedure based on the automatic installation command, so that the intermediate relay module generates the first control signal. For details, please refer to the relevant descriptions in the above system embodiments; they will not be repeated here.

[0090] In step S13, the installation device is controlled based on the first control signal to realize the installation of the scaffolding, and the installation device is controlled based on the second control signal to realize the installation and dismantling of the scaffolding. For details, please refer to the relevant descriptions in the above system embodiments, which will not be repeated here.

[0091] It should be noted that the foregoing explanation of the embodiment of the PLC-based dual-mode roadway support control system also applies to the PLC-based dual-mode roadway support control method of this embodiment, and will not be repeated here.

[0092] The sequence numbers of the embodiments disclosed above are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0093] In the PLC-based dual-mode roadway support control method disclosed herein, a mode switching command is acquired, including a command to switch to manual mode and a command to switch to automatic mode. If a command to switch to automatic mode is received, the main control cabinet generates a first control signal based on an automatic installation command. If a command to switch to manual mode is received, the main control cabinet acquires a cylinder adjustment command sent by a remote control box to generate a second control signal. Based on the first or second control signal, the hydraulic cylinder unit of the installation device is controlled by a hydraulic device to realize the installation and dismantling of the support frame. In this case, the control device, hydraulic device, and installation device are comprehensively utilized. The hydraulic device and installation device are remotely controlled by the control device to realize the installation and dismantling of the support frame, avoiding the need for manual support for the installation and dismantling of the support frame. This achieves remote support frame support for the roadway, thereby protecting the safety and health of coal miners. The control method disclosed herein is applicable to the intelligent transformation of coal mining equipment. Signals are transmitted to a data acquisition card via buttons on a remote control box. The data acquisition card exchanges data with a PLC via the RS485 communication protocol. The PLC controls the on / off state of corresponding relays to control the hydraulic device for roadway support, thereby controlling the hydraulic cylinders. The movement of the hydraulic cylinders pushes the support frame to a designated position, ultimately completing the support process. The control process has both manual and automatic modes. The manual mode can be used for the installation and dismantling of the support frame, while the automatic mode enables unmanned remote installation of the support frame. It also adds emergency stop and timeout control for the hydraulic cylinders. Compared to manual support, this control method offers higher safety and better adaptability.

[0094] The accompanying drawings show structural schematic diagrams according to embodiments disclosed in this invention. These drawings are not drawn to scale, and some details have been enlarged for clarity, and some details may have been omitted. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0095] It should be understood that the various forms of processes shown above can be used to rearrange, add, or delete steps. For example, the steps described in this disclosure can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution disclosed in this disclosure can be achieved, and this disclosure does not impose any restrictions here.

[0096] The specific embodiments described above do not constitute a limitation on the scope of protection of this disclosure. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this disclosure should be included within the scope of protection of this disclosure.

Claims

1. A PLC-based dual-mode roadway support control system, characterized in that, The dual-mode includes a manual mode and an automatic mode. The support control system includes a control device, a hydraulic device, and an installation device. The control device is connected to the installation device via the hydraulic device. The control device includes a main control cabinet and a remote control box, which are connected. The remote control box is used to send a mode switching command to the main control cabinet. The mode switching command includes a manual mode switching command and an automatic mode switching command. When the main control cabinet receives the automatic mode switching command, it generates a first control signal based on an automatic installation command. When the main control cabinet receives the manual mode switching command, it acquires the cylinder adjustment command sent by the remote control box to generate a second control signal. The hydraulic device includes a hydraulic valve group, which is used to control the installation device based on a first control signal or a second control signal from the control device to realize the installation and dismantling of the scaffolding; The installation device includes two single-sided installation devices arranged in a mirror-symmetric manner, each single-sided installation device including a hydraulic cylinder unit for controlling the scaffold and the installation arm.

2. The PLC-based dual-mode roadway support control system as described in claim 1, characterized in that: The remote control box includes a data acquisition card module and a switch element module. One end of the data acquisition card module is connected to the switch element module, and the other end of the data acquisition card module is connected to the main control cabinet. The switch element module includes a first switch element unit and a second switch element unit. The first switch element unit is used to generate a mode switching command, and the second switch element unit is used to generate a hydraulic cylinder adjustment command. The data acquisition card module is used to send the mode switching command and the hydraulic cylinder adjustment command to the main control cabinet.

3. The PLC-based dual-mode roadway support control system as described in claim 2, characterized in that: The main control cabinet includes a PLC main control module and an intermediate relay module. One end of the PLC main control module is connected to the data acquisition card module, and the other end of the PLC main control module is connected to the hydraulic device via the intermediate relay module. The PLC main control module is used to control the on / off state of the intermediate relay module according to the automatic installation command and a preset installation process when it receives the automatic mode switching command, so that the intermediate relay module generates a first control signal. It is also used to control the on / off state of the intermediate relay module according to the cylinder adjustment command when it receives the manual mode switching command, so that the intermediate relay module generates a second control signal.

4. The PLC-based dual-mode roadway support control system as described in claim 3, characterized in that: The cylinder unit includes multiple cylinders, the number of which is equal to the number of hydraulic valve groups, and each cylinder is controlled by one hydraulic valve group.

5. The PLC-based dual-mode roadway support control system as described in claim 1, characterized in that, The hydraulic cylinder unit includes a first hydraulic cylinder unit, a second hydraulic cylinder unit, and a third hydraulic cylinder unit. The first hydraulic cylinder unit is used to control the movement of the scaffold, the second hydraulic cylinder unit is used to lock the scaffold, and the third hydraulic cylinder unit is used to control the extension of the mounting arm.

6. The PLC-based dual-mode roadway support control system as described in claim 2, characterized in that: The switching element module also includes an emergency stop button, which is used to generate an emergency stop signal and a first recovery signal. The data acquisition card module is also used to send the emergency stop signal or the first recovery signal to the main control cabinet. The main control cabinet controls the dual-mode roadway support control system to stop or resume operation based on the emergency stop signal or the first recovery signal.

7. The PLC-based dual-mode roadway support control system as described in claim 2, characterized in that: The switching element module also includes a timeout recovery button, which is used to generate a second recovery signal when the fault is cleared. The data acquisition card module is also used to send the second recovery signal to the main control cabinet, and the main control cabinet controls the dual-mode roadway support control system to resume operation based on the second recovery signal.

8. The PLC-based dual-mode roadway support control system as described in claim 2, characterized in that: The remote control box also includes multiple indicator lights, which are connected to the data acquisition card module. The indicator lights turn on and off based on the status signal output by the data acquisition card module to indicate different states of the dual-mode roadway support control system.

9. A PLC-based dual-mode roadway support control method employing the PLC-based dual-mode roadway support control system as described in any one of claims 1-8, characterized in that, include: Obtain mode switching instructions, including instructions to switch to manual mode and instructions to switch to automatic mode; If an automatic mode switching command is received, the main control cabinet generates a first control signal based on the automatic installation command. If the manual mode switching command is received, the main control cabinet obtains the cylinder adjustment command sent by the remote control box to generate a second control signal. Based on the first control signal or the second control signal, the hydraulic cylinder unit of the installation device is controlled by a hydraulic device to realize the installation and dismantling of the scaffold.

10. The PLC-based dual-mode roadway support control method as described in claim 9, characterized in that, The main control cabinet includes a PLC main control module and an intermediate relay module. If an automatic mode activation command is received, the main control cabinet generates a first control signal based on the automatic installation command, including: Upon receiving the command to switch to automatic mode, the PLC main control module controls the on / off state of the intermediate relay module according to the preset installation process based on the automatic installation command, so that the intermediate relay module generates the first control signal.

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