Anchoring rod and cable automatic tensioning system and control method

Abstract

The present application belongs to the technical field of automatic control of coal mine underground anchor rod and anchor cable drilling frame, and specifically relates to an anchor rod and anchor cable automatic tensioning system and a control method. The system comprises a hydraulic electromagnetic valve group for driving a hydraulic oil cylinder actuator to act; a display box for displaying the state of each control parameter and real-time parameters of the automatic tensioning system; a controller for real-time monitoring of input and output states, real-time display of a real-time curve and a target value of tensioning force in the automatic tensioning process, and fault alarm; an emergency stop button for a stop button in emergency situations to prevent safety accidents; a change-over switch for realizing automatic tensioning and manual tensioning of the anchor cable tensioning instrument; a pressure sensor for measuring the operating pressure of the tensioning oil cylinder; an anchor cable stress sensor for measuring the tensioning force of the anchor cable tensioning instrument; and an electromagnetic valve control box for recording and storing real-time operating parameters of the tensioning instrument in the operating process.

Description

Technical Field

[0001] This invention belongs to the field of automatic control technology for underground anchor bolt and cable drilling frames in coal mines, specifically an automatic tensioning system and control method for anchor bolts and cables. Background Technology

[0002] Underground roadway excavation and support in coal mines is one of the key technologies in underground mining. With the increasing mechanization of underground roadway excavation equipment, the requirements for the automation level of underground support equipment are becoming increasingly higher. After the roadway is excavated, anchor bolt and cable equipment is needed to support the roadway. The existing anchor bolt and cable support technology process mainly includes multiple steps such as laying the network, installing steel strips, positioning, drilling, filling anchoring agent, installing anchor cables, mixing, and anchor cable tensioning. At present, the overall technical level of anchor cable support in China is relatively backward. Currently, the tensioning equipment purchased from outside the market is mainly operated manually, with a low degree of mechanization. Anchor cable construction can only use the pressure value of the booster pump to infer the tension force of the anchor cable, but the actual tension force of the anchor cable is unknown, and it is difficult to achieve with existing technical means. This poses a great challenge to the on-site construction and quality inspection of anchor cables. The low degree of automation and poor safety of anchor cable tensioning make it difficult to achieve automated operation of anchor cable tensioning in underground roadway support in coal mines. Summary of the Invention

[0003] In order to at least partially solve one of the technical problems in the related art, the present invention provides an automatic tensioning system and control method for anchor bolts and cables.

[0004] This invention adopts the following technical solution: an automatic tensioning system for anchor bolts and cables, comprising:

[0005] Hydraulic solenoid valve assembly is used to drive the hydraulic cylinder actuator.

[0006] The display box is used to display the status and real-time parameters of various control parameters in the automatic tensioning system, and can also be used to set the automatic tensioning data parameters;

[0007] The controller monitors the input and output status in real time, displays the real-time curve and target value of the tension force during automatic tensioning, provides fault alarms, and plots the curves of pressure and anchor cable stress changes.

[0008] The emergency stop button is used to stop the vehicle in an emergency to prevent accidents.

[0009] The selector switch is used to enable automatic and manual tensioning of the anchor cable tensioner.

[0010] A pressure sensor is used to measure the operating pressure of the tensioning cylinder;

[0011] Anchor cable stress sensor, used to measure the tension force of anchor cable tensioner;

[0012] The solenoid valve control box records and stores the operating parameters of the tensioning instrument in real time during operation.

[0013] In some embodiments, the solenoid valve control box includes an embedded controller and its expansion modules, a switching power supply, a relay isolation module, and a data storage module. The PLC expansion module includes a digital input module, a digital output module, an analog input module, and a communication module. The memory records and stores the data of the embedded controller in real time over a long period of time via the CAN bus, including the operating parameters of the tensioning device during operation, facilitating data analysis, equipment maintenance, and fault diagnosis analysis. The memory stores data only when the anchor cable tensioning system starts working, triggered by hardware.

[0014] In some embodiments, the changeover switch has three positions: tension, relaxation, and one-button start;

[0015] When the selector switch is turned to the tension position, the anchor cable tensioner begins manual tensioning.

[0016] When the selector switch is turned to the relaxation position, the anchor cable tensioner begins to relax the tension.

[0017] When the selector switch is turned to the one-button start position, the anchor cable tensioner will automatically tension the cable.

[0018] A control method for an automatic tensioning system for anchor bolts and cables includes manual tensioning control, the specific process of which is as follows:

[0019] 1) The controller reads data from each sensor;

[0020] 2) The embedded controller determines the status and position of each actuator based on the collected data;

[0021] 3) Set the tension of the control system;

[0022] 4) Operate the selector switch to the "Tension" button to activate the jack cylinder and measure the tension value;

[0023] 5) If the tension value is greater than the system target value, repeat the action of the jack cylinder; if the tension value is less than or equal to the system target value, proceed to the next step.

[0024] 6) Once the pressure sensor stabilizes, press the "Relax" button on the switch to retract the jack cylinder and complete the anchor bolt and cable tensioning.

[0025] In some embodiments, step 2) of manual tensioning control includes: the anchor cable stress sensor collects the stress of the jack in real time and transmits the stress data of the sensor to the communication extension module of the solenoid valve control box; at the same time, the hydraulic pressure value of the tensioning cylinder is transmitted to the analog input module of the embedded controller; the embedded controller displays all data parameters in real time on the host computer interface on the display box and stores the anchor (cable) stress sensor, pressure sensor and their operating status data in the memory.

[0026] In some embodiments, automatic tensioning control is also included, the specific process of which is as follows:

[0027] 1) The controller reads data from each sensor;

[0028] 2) The embedded controller determines the status and position of each actuator based on the collected data;

[0029] 3) Set the tension of the control system;

[0030] 4) Switch the selector switch to the "One-button Start" button. The jack cylinder will activate, and the automatic tensioning system will start operating.

[0031] 5) When the anchor bolt and anchor cable tension reaches the set value, the jack cylinder automatically disengages, and the automatic tensioning is completed.

[0032] In some embodiments, step 4) of the automatic tensioning control includes:

[0033] After the automatic anchor cable tensioning system reaches the set pressure value, it holds for 5 seconds and then the jack automatically retracts. When the control system detects that the pressure of each cylinder and the stress value of the anchor cable have returned to the initial value, the control system stops outputting.

[0034] In some embodiments, the anchor cable tension force adopts feedback closed-loop control. Combining the data accumulation of the anchor cable stress sensor and the pressure closed-loop control of the tensioning system cylinder, the tension force of the jack is controlled to achieve closed-loop control of the hydraulic pressure of the anchor cable tensioning system as the control quantity. The tension force relationship is y=Kp*e(t), where Kp is the output adjustment proportional coefficient of the solenoid valve, e(t)=tension force setting value-real-time tension force acquisition value, and the tension force value K=a*y1, where a is the proportional coefficient of the pressure sensor and stress sensor, and y1 is the pressure value of the anchor cable tensioning cylinder.

[0035] Compared with existing technologies, this invention automates the anchor cable tensioning process in anchor bolt and cable support operations. It enables one-click automatic tensioning, real-time monitoring of various mining anchor cable tensioning devices, and remote tensioning via a human-machine interface platform. This reduces the workload of operators, improves worker safety, enhances the automation level of anchor cable support operations, provides technical support for the automation of anchor bolt and cable support technology, and improves the efficiency of anchor cable support during roadway excavation. Attached Figure Description

[0036] Figure 1 This is a block diagram of an automatic tensioning system for anchor bolts and cables.

[0037] Figure 2 A block diagram illustrating the manual control principle of an automatic tensioning system for anchor bolts and cables;

[0038] Figure 3 This is a block diagram illustrating the automatic control principle of an automatic tensioning system for anchor bolts and cables. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] In the embodiments provided by the present invention, the automatic tensioning system for anchor bolts and cables includes a hydraulic solenoid valve group, a display box, an emergency stop button, a selector switch, a jack, a solenoid valve control box, an anchor bolt (cable) stress sensor, a pressure sensor, etc.

[0041] The hydraulic solenoid valve assembly is used to drive the hydraulic cylinder actuator. In this system, it mainly consists of a tension cylinder and a release cylinder.

[0042] The display box is mainly used to display the status and real-time parameters of various control parameters in the automatic tensioning system in real time. It can also set the automatic tensioning data parameters, monitor the real-time input and output status of the controller, display the real-time curve and target value of the tension force during the automatic tensioning process, and provide fault alarms. It can also draw the pressure and anchor stress change curves and display and store the tension pressure and anchor stress data according to different sampling time intervals.

[0043] The emergency stop button is used to stop the vehicle in an emergency to prevent accidents.

[0044] The pressure sensor is used to measure the operating pressure of the tensioning cylinder;

[0045] Anchor bolt (cable) stress sensors are used to measure the tension force of anchor cable tensioners;

[0046] The selector switch is used to enable automatic and manual tensioning of the anchor cable tensioner;

[0047] The solenoid valve control box mainly consists of an embedded controller and its expansion modules, a switching power supply, a relay isolation module, and a data storage module. The PLC expansion module mainly consists of a digital input module, a digital output module, an analog input module, and a communication module. The memory records and stores the data of the embedded controller in real time over a long period of time via the CAN bus, including the operating parameters of the tensioning device during operation. This facilitates data analysis and equipment maintenance, enables fault diagnosis and analysis, and helps solve potential problems in the system, thereby improving the reliability of the anchor cable tensioning system. The memory can be triggered by hardware to store data only when the anchor cable tensioning system starts working, increasing the occupancy rate of effective data in the memory card.

[0048] A control method for an automatic tensioning system for anchor bolts and cables includes manual tensioning control and automatic tensioning control methods.

[0049] Manual tensioning control, the specific process is as follows:

[0050] 1) The controller reads data from each sensor.

[0051] 2) The embedded controller determines the status and position of each actuator by collecting the data.

[0052] Step 2 of the manual tensioning control includes: the anchor cable stress sensor collects the stress of the jack in real time and transmits the stress data of the sensor to the communication expansion module of the solenoid valve control box. At the same time, the hydraulic pressure value of the tensioning cylinder is transmitted to the analog input module of the embedded controller. The embedded controller displays all data parameters in real time on the host computer interface on the display box and stores the anchor (cable) stress sensor, pressure sensor and their action status data in the memory.

[0053] 3) Set the tension of the control system.

[0054] 4) Operate the selector switch to the "Tension" button to activate the jack cylinder and measure the tension value.

[0055] 5) If the tension value is greater than the system set target value, repeat the action of the jack cylinder; if the tension value is less than or equal to the system set target value, proceed to the next step.

[0056] 6) Once the pressure sensor stabilizes, press the "Relax" button on the switch to retract the jack cylinder and complete the anchor bolt and cable tensioning.

[0057] Automatic tensioning control, the specific process is as follows:

[0058] 1) The controller reads data from each sensor.

[0059] 2) The embedded controller determines the status and position of each actuator by collecting the data.

[0060] 3) Set the tension of the control system.

[0061] 4) Switch the selector switch to the "One-key Start" button. The jack cylinder will activate, and the automatic tensioning system will start running.

[0062] Step 4 of the automatic tensioning control includes:

[0063] After the automatic anchor cable tensioning system reaches the set pressure value, it holds for 5 seconds and then the jack automatically retracts. When the control system detects that the pressure of each cylinder and the stress value of the anchor cable have returned to the initial value, the control system stops outputting.

[0064] The anchor cable tension is controlled by feedback closed loop. It combines the data accumulation of the anchor cable stress sensor and the pressure closed loop control of the hydraulic cylinder of the tensioning system to control the tension force of the jack. This achieves closed loop control of the hydraulic pressure of the anchor cable tensioning system as the control quantity. The tension force relationship is y=Kp*e(t), where Kp is the proportional coefficient of the solenoid valve output adjustment, e(t) = tension force setting value - real-time tension force acquisition value, and the tension force value K=a*y1, where a is the proportional coefficient of the pressure sensor and stress sensor, and y1 is the pressure value of the anchor cable tensioning cylinder.

[0065] 5) When the anchor bolt and anchor cable tension reaches the set value, the jack cylinder automatically disengages, and the automatic tensioning is completed.

[0066] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A control method for an automatic tensioning system for anchor bolts and cables, characterized in that, An automatic anchor bolt and cable tensioning system is adopted, including: Hydraulic solenoid valve assembly is used to drive the hydraulic cylinder actuator. The display box is used to display the status and real-time parameters of various control parameters in the automatic tensioning system, and to set the automatic tensioning data parameters. The controller monitors the input and output status in real time, displays the real-time curve and target value of the tension force during automatic tensioning, provides fault alarms, and plots the curves of pressure and anchor cable stress changes. The emergency stop button is used to stop the vehicle in an emergency to prevent accidents. The selector switch is used to enable automatic and manual tensioning of the anchor cable tensioner. A pressure sensor is used to measure the operating pressure of the tensioning cylinder; Anchor cable stress sensor, used to measure the tension force of anchor cable tensioner; The solenoid valve control box records and stores the operating parameters of the tensioning instrument in real time during operation. The selector switch has three positions: tension, relaxation, and one-button start; When the selector switch is turned to the tension position, the anchor cable tensioner begins manual tensioning. When the selector switch is turned to the relaxation position, the anchor cable tensioner begins to relax the tension. When the selector switch is turned to the one-button start position, the anchor cable tensioner automatically tensions the cable. This includes automatic tensioning control, the specific process of which is as follows: 1) The controller reads data from each sensor; 2) The embedded controller determines the status and position of each actuator based on the collected data; 3) Set the tension of the control system; 4) Switch the selector switch to the "One-button Start" button. The jack cylinder will activate, and the automatic tensioning system will start operating. 5) When the anchor bolt and anchor cable tension reaches the set value, the jack cylinder automatically disengages, and the automatic tensioning is completed; The anchor cable tension is controlled by a feedback closed-loop system. This system combines data accumulation from the anchor cable stress sensor with closed-loop control of the hydraulic cylinder pressure in the tensioning system to achieve closed-loop control where the hydraulic pressure of the anchor cable tensioning system is the control variable. The tension force is expressed as y = Kp. e(t), Kp is the proportional coefficient for adjusting the output of the solenoid valve, e(t) = tension setpoint - real-time acquired tension value, tension value K = a y1,a is the proportional coefficient of the pressure sensor and the stress sensor, and y1 is the pressure value of the anchor cable tensioning cylinder.

2. The control method for the automatic tensioning system of anchor bolts and cables according to claim 1, characterized in that, The solenoid valve control box includes an embedded controller and its expansion modules, a switching power supply, a relay isolation module, and a data storage module. The PLC expansion module includes a digital input module, a digital output module, an analog input module, and a communication module. The memory records and stores data from the embedded controller in real time via a CAN bus, including the operating parameters of the tensioning device during operation, facilitating data analysis, equipment maintenance, and fault diagnosis. The memory uses a hardware triggering method to store data only when the anchor cable tensioning system starts working.

3. The control method for the automatic tensioning system of anchor bolts and cables according to claim 1, characterized in that, It also includes manual tension control, the specific process of which is as follows: 1) The controller reads data from each sensor; 2) The embedded controller determines the status and position of each actuator based on the collected data; 3) Set the tension of the control system; 4) Operate the selector switch to the "Tension" button to activate the jack cylinder and measure the tension value; 5) If the tension value is greater than the system's target value, repeat the action of the jack cylinder; If the tension value is less than or equal to the system-set target value, proceed to the next step. 6) Once the pressure sensor stabilizes, press the "Release" button on the switch to retract the jack cylinder and complete the anchor bolt and cable tensioning.

4. The control method for the automatic tensioning system of anchor bolts and cables according to claim 3, characterized in that, Step 2 of the manual tensioning control includes: the anchor cable stress sensor collects the stress of the jack in real time and transmits the stress data of the sensor to the communication expansion module of the solenoid valve control box. At the same time, the hydraulic pressure value of the tensioning cylinder is transmitted to the analog input module of the embedded controller. The embedded controller displays all data parameters in real time on the host computer interface on the display box and stores the anchor cable stress sensor, pressure sensor and their action status data in the memory.

5. The control method for the automatic tensioning system of anchor bolts and cables according to claim 1, characterized in that, Step 4 of the automatic tensioning control includes: After the automatic anchor cable tensioning system reaches the set pressure value, it holds for 5 seconds and then the jack automatically retracts. When the control system detects that the pressure of each cylinder and the stress value of the anchor cable have returned to the initial value, the control system stops outputting.

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