A real-time monitoring system for top coal flow state based on pressure pillow uniform distribution cluster

Abstract

The application provides a real-time monitoring system for the state of a top coal flow based on pressure pillow uniform distribution clusters, and relates to the field of top coal mining equipment and intelligent control technology. The system comprises a top coal hydraulic support, pressure pillows, a scraper conveyor, an information transmission cable, a signal processing and visualization device, a signal acquisition device, a hydraulic pipeline and a hydraulic control device. The shield beam and the tail beam of the top coal hydraulic support are uniformly arranged with multiple pressure pillows. The pressure pillows comprise signal contacts and contact signal lines. Broken top coal and broken gangue are affected by gravity and fall onto the upper surface of the shield beam, and then fall onto the upper surface of the tail beam, and then fall into the scraper conveyor. The pressure pillows send the pressure signals to the signal acquisition device through the information transmission cable after collecting the pressure signals. The signal processing and visualization device fits the spatial motion trajectory of the coal flow particles and draws the spatial curve of the coal flow motion flow state. The system can improve the coal releasing efficiency, improve the coal releasing quality and ensure safe mining.

Description

Technical Field

[0001] This invention relates to the field of top coal caving mining equipment and intelligent control technology, and in particular provides a real-time monitoring system for the coal flow status of top coal caving based on a uniformly distributed cluster of pressure pillows. Background Technology

[0002] With the promotion of smart mines, their construction aims to improve coal mine production efficiency, reduce safety risks, optimize resource utilization, and promote the transformation and upgrading of the coal mining industry. Automated monitoring of the top coal caving process in fully mechanized longwall mining, based on technologies such as intelligent detection, big data computing, and artificial intelligence analysis, is key to building smart mines.

[0003] In existing technologies, the monitoring and automated control of the top-coal caving mining process rarely involves monitoring the coal discharge space behind the hydraulic supports. However, the movement of the coal flow behind the supports not only affects mining efficiency and coal quality but also, to some extent, the stability and safety of the supports. Monitoring the movement of the coal flow behind the supports can help miners better understand the coal discharge situation in real time, ensuring occupational safety, accelerating coal discharge efficiency, and improving coal quality. Further improvements to existing top-coal caving systems are necessary to standardize mining processes, rationally plan coal discharge procedures, and ensure both safety and quality. Summary of the Invention

[0004] To improve the efficiency of top coal caving mining, enhance coal discharge quality, and ensure safe mining, this invention provides a real-time monitoring system for the coal flow status of top coal caving based on a uniformly distributed cluster of pressure pillows. The specific technical solution is as follows.

[0005] A real-time monitoring system for the coal flow status of top coal caving based on a uniformly distributed cluster of pressure pillows includes a top coal caving hydraulic support, pressure pillows, a scraper conveyor, an information transmission cable, a signal processing and visualization device, a signal acquisition device, hydraulic pipelines, and a hydraulic control device. Multiple pressure pillows are evenly distributed on the shield beam and tail beam of the top coal caving hydraulic support. Each pressure pillow includes signal contacts and contact signal lines. The contact signal lines are connected to the signal acquisition device via the information transmission cable, and the signal acquisition device is connected to the signal processing and visualization device. The scraper conveyor is located below the tail beam, and the hydraulic control device is connected to the tail beam jacks via hydraulic pipelines.

[0006] Preferably, the hydraulic support for top coal caving is arranged below the top coal seam, and above the top coal seam is a gangue rock layer; after the top coal seam and gangue rock layer are crushed, flowing crushed top coal and crushed gangue are generated.

[0007] Preferably, the crushed top coal and crushed gangue roll sequentially on the upper surface of the shield beam, triggering the pressure pillow. The pressure pillow has signal contacts evenly arranged inside, and the signal contacts are connected to the contact signal lines. The pressure pillow collects pressure and vibration information.

[0008] Preferably, the signal acquisition device acquires and stores the monitoring signals from the pressure pillow at each time point, and the signal processing and visualization device obtains the real-time signal matrix of the pressure pillow.

[0009] A further preferred embodiment is that the signal processing and visualization device acquires the position coordinates of all pressure pillows and calls up the position coordinates according to the working posture of the top coal caving hydraulic support; the signal processing and visualization device numbers and names the coal particles in contact with the pressure pillows according to the time nodes, and through big data processing and data separation methods, processes the signal into a four-dimensional matrix data of coal particle number, time node, position coordinates and pressure value, and then fits the four-dimensional data into the spatial motion trajectory of each coal particle, and draws the spatial curve of the coal flow motion state.

[0010] A further preferred embodiment is to determine the coal flow motion state and coal flow attributes based on a four-dimensional matrix of coal particle numbers, time nodes, location coordinates, and pressure values. The coal flow motion state includes laminar flow, turbulent flow, and flow direction from upper left to lower right, from top to bottom, or from upper right to lower left. The coal flow attributes are either pure coal or interbedded with gangue.

[0011] More preferably, a laminar flow indicates that the coal flow is very smooth, while a turbulent flow indicates that the coal flow is stuck or blocked. The hydraulic control device adjusts the opening of the coal discharge port according to the coal flow state and adjusts the swing tail beam to disturb the coal flow; it judges the direction of the coal flow based on the coal flow movement state and controls the opening and closing sequence of the coal discharge port; it judges the gangue content based on the coal flow properties and controls the opening and closing of the coal discharge port.

[0012] The beneficial effects of the real-time monitoring system for top coal caving flow status based on a uniformly distributed cluster of pressure pillows provided by this invention are as follows: the hydraulic supports of the top coal caving system can achieve automated control to improve coal caving efficiency and ensure coal caving safety by monitoring the coal flow conditions; the system uses pressure pillow structures to uniformly arrange and determine coordinates on the shield beam and tail beam, and comprehensively obtains a four-dimensional data matrix of coal particle number, time node, position coordinates, and pressure value, thereby accurately judging the coal flow movement state and drawing spatial curves, realizing automated and intelligent mining. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the layout of a real-time monitoring system for the coal flow status of top coal caving based on a uniformly distributed cluster of pressure pillows.

[0014] Figure 2 This is a schematic diagram of the hydraulic support structure for top coal caving;

[0015] Figure 3 This is a schematic diagram of the arrangement of the pressure pillows;

[0016] Figure 4 This is a schematic diagram of the arrangement of the pressure pillow signal contacts;

[0017] Figure 5 This is a schematic diagram illustrating the principle of real-time monitoring of top coal flow status based on the uniformly distributed cluster of pressure pillows.

[0018] In the diagram: 1-Top coal caving hydraulic support, 2-Gange rock layer, 3-Top coal seam, 4-Crushed gangue, 5-Crushed top coal, 6-Pressure pillow distribution, 7-Scraper conveyor, 8-Information transmission cable, 9-Signal processing and visualization device, 10-Signal acquisition device, 11-Hydraulic pipeline, 12-Hydraulic control device, 101-Tail beam, 102-Tail beam jack, 103-Shield beam, 61-Pressure pillow of shield beam, 62-Pressure pillow of tail beam, 601-Signal contact, 602-Contact signal line. Detailed Implementation

[0019] Combination Figures 1 to 5 As shown, a specific implementation of the real-time monitoring system for top coal caving status based on a uniformly distributed cluster of pressure pillows provided by the present invention will be described.

[0020] A real-time monitoring system for top coal caving flow status based on a uniformly distributed cluster of pressure pillows includes a top coal caving hydraulic support 1, a gangue rock layer 2, a top coal layer 3, crushed gangue 4, crushed top coal 5, pressure pillows 6, a scraper conveyor 7, an information transmission cable 8, a signal processing and visualization device 9, a signal acquisition device 10, hydraulic pipelines 11, and a hydraulic control device 12. This system monitors the coal caving process in real time through the pressure pillows 6 and controls the top coal caving hydraulic support to stably cave coal based on the monitoring results. Multiple pressure pillows 6 are evenly distributed on the shield beam and tail beam of the top coal caving hydraulic support 1. The number of pressure pillows 6 is determined according to the arrangement and size of the shield beam 103 and tail beam 101. Each pressure pillow 6 includes a signal contact 601 and a contact signal line 602. The contact signal line 602 is connected to the signal acquisition device 10 via the information transmission cable 8, and the signal acquisition device 10 is connected to the signal processing and visualization device 9. The scraper conveyor 7 is arranged below the tail beam 101. Coal and gangue discharged from the coal discharge port are stored on the scraper conveyor 7. The hydraulic control device 12 is connected to the tail beam jack 102 through the hydraulic pipeline 11, thereby controlling the opening and closing of the coal discharge port.

[0021] The top coal caving hydraulic support 1 is positioned below the top coal seam 3, with the gangue rock layer 2 above it. After the top coal seam 3 and gangue rock layer 2 are broken, flowing broken top coal 5 and broken gangue 4 are produced. During the top coal caving mining process, the tail beam jack 102 is controlled by the hydraulic control device 12 to open the hydraulic support's coal discharge port 13. Subsequently, the top coal seam 3 and gangue rock layer 2 above the top coal caving hydraulic support 1 are successively broken under the action of mine pressure and gravity, producing flowing broken top coal 5 and broken gangue 4 respectively. The broken top coal 5 or broken gangue 4 falls onto the upper surface of the shield beam 103 under the influence of gravity, and continues to roll down along the upper surface of the shield beam 103 to the upper surface of the tail beam 102, finally falling onto the scraper conveyor 7.

[0022] The crushed top coal 5 and crushed gangue 4 roll on the upper surface of the shield beam, sequentially triggering the pressure pillows 6. Signal contacts 601 are evenly distributed inside the pressure pillows 6, connected to signal lines 602. The pressure pillows 6 collect pressure and vibration information. When the crushed top coal 5 or crushed gangue 4 rolls on the upper surface of the shield beam 103, the impact force generated by its rolling will sequentially trigger the beam pressure pillows 61 of the shield beam along the rolling path. After the pressure pillows 61 of the shield beam are triggered, the trigger signal will be transmitted to the signal acquisition device 10 through the information transmission cable 8. Similarly, when the crushed top coal 5 or crushed gangue 4 rolls onto the upper surface of the tail beam 101, the pressure pillows 62 of the tail beam will also transmit the trigger signal along the rolling path to the signal acquisition device 10.

[0023] The pressure pillow 6 consists of 36 pressure pillows 61 for the shield beams and 24 pressure pillows 62 for the tail beams, evenly distributed on the upper surfaces of the shield beam 103 and the tail beam 101, respectively. The 36 pressure pillows 61 for the shield beams are arranged in 6 rows and 6 columns, while the 24 pressure pillows 62 for the tail beams are arranged in 4 rows and 6 columns. Each pressure pillow contains 9 rows and 9 columns of signal contacts 601, which communicate with the information transmission cable 8 via contact signal lines 602. This means that one pressure pillow can collect pressure vibration data from 81 contact positions. The evenly distributed pressure pillows 6 form a pressure pillow cluster, capable of collecting 4860 pressure vibration data points at a single time point.

[0024] The signal acquisition device 10 acquires and stores the monitoring signals from the pressure pillow at each time point, and the signal processing and visualization device obtains the real-time signal matrix of the pressure pillow 6. 4860 signals from the uniformly distributed cluster of pressure pillows are indexed by time and sent to the signal processing and visualization device 9 as the real-time signal matrix of the uniformly distributed cluster of pressure pillows.

[0025] The signal processing and visualization device 9 acquires the position coordinates of all pressure pillows and retrieves these coordinates based on the working posture of the top coal caving hydraulic support 1. The device numberes and names the coal particles in contact with the pressure pillows according to time nodes. Through big data processing and data separation methods, it processes the signals into a four-dimensional matrix of coal particle numbers, time nodes, position coordinates, and pressure values. This four-dimensional data is then fitted to the spatial motion trajectory of each coal particle, and a spatial curve of the coal flow motion is plotted.

[0026] The coal flow motion state and coal flow attributes are determined based on a four-dimensional matrix of coal particle number, time node, location coordinates, and pressure value. The coal flow motion state includes laminar flow, turbulent flow, and flow direction from upper left to lower right, from top to bottom, and from upper right to lower left. The coal flow attributes are either pure coal or interbedded with gangue.

[0027] A laminar flow indicates smooth coal flow, while a turbulent flow indicates blockage or obstruction. The hydraulic control device adjusts the opening of the coal discharge port based on the coal flow status and uses the swing tail beam to agitate the coal flow. It also determines the coal flow direction based on the flow's movement and controls the opening and closing sequence of the coal discharge port. Furthermore, it determines the gangue content based on the coal flow properties and controls the opening and closing of the coal discharge port accordingly. The coal flow direction monitoring function displays the specific angle of the coal flow direction, providing a reference for top coal caving processes, especially in steeply inclined coal seams, helping miners determine the coal flow direction and correctly control the opening and closing sequence of the coal discharge ports in the multi-faceted coal caving operation. The coal flow property monitoring function identifies the presence and percentage of gangue in the coal flow based on pressure changes in the pressure pillow, providing a time reference during mining and helping miners determine whether the top coal has been completely discharged and whether gangue has appeared, allowing for timely closure of the coal discharge port to prevent over- or under-discharge of top coal, thereby improving the top coal extraction rate and reducing the gangue content.

[0028] The system's top coal caving hydraulic support can achieve automated control to improve coal caving efficiency and ensure coal caving safety by monitoring the coal flow. The system uses a pressure pillow structure to evenly distribute and determine the coordinates on the shield beam and tail beam, and comprehensively obtains a four-dimensional data matrix of coal particle number, time node, position coordinates, and pressure value, thereby accurately judging the coal flow movement state and drawing spatial curves, realizing automated and intelligent mining.

[0029] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A real-time monitoring system for the state of the coal flow of the top coal caving based on the pressure pillow uniform distribution cluster, characterized in that, The application relates to a coal caving hydraulic support, a pressure pillow, a scraper conveyor, an information transmission cable, a signal processing and visualization device, a signal acquisition device, a hydraulic pipeline and a hydraulic control device, multiple pressure pillows are uniformly arranged on a shield beam and a tail beam of the coal caving hydraulic support, the pressure pillow comprises a signal contact and a contact signal line, the contact signal line is connected with the signal acquisition device through the information transmission cable, the signal acquisition device is connected with the signal processing and visualization device; the scraper conveyor is arranged below the tail beam, the hydraulic control device is connected with the tail beam jack through the hydraulic pipeline; the coal caving hydraulic support is arranged below a top coal layer, and a gangue rock layer is arranged above the top coal layer; the top coal layer and the gangue rock layer are broken to generate broken top coal and broken gangue; the broken top coal and the broken gangue roll on the upper surface of the shield beam to trigger the pressure pillows in sequence, the pressure pillows are uniformly arranged with the signal contacts inside, the signal contacts are connected with the contact signal lines, and the pressure pillows collect pressure and vibration information; the signal acquisition device collects and stores the monitoring signals from the pressure pillows at each time node, and the signal processing and visualization device obtains a real-time signal matrix of the pressure pillows; the signal processing and visualization device obtains the position coordinates of all the pressure pillows, and calls the position coordinates according to the working posture of the coal caving hydraulic support; the signal processing and visualization device numbers and names the coal particles contacting the pressure pillows according to the time nodes, processes the signals into four-dimensional matrix data of the coal particle numbers, time nodes, position coordinates and pressure values through big data processing and data separation methods, fits the four-dimensional data into the space movement trajectories of the coal particles, and draws the space curves of the coal flow movement flow state; the four-dimensional matrix data of the coal particle numbers, time nodes, position coordinates and pressure values are used to judge the coal flow movement state and the coal flow attribute; the coal flow movement state includes laminar flow, turbulent flow, left-up to right-down coal flow direction, straight-up to straight-down coal flow direction and right-up to left-down coal flow direction; the coal flow attribute is pure coal state or gangue state; the laminar flow state indicates that the coal flow is very smooth, the turbulent flow state indicates that the coal flow is blocked or jammed, the hydraulic control device adjusts the coal discharging opening degree according to the coal flow state and adjusts the swing tail beam to disturb the coal flow; the coal flow direction is judged according to the coal flow movement state to control the opening and closing sequence of the coal discharging opening; the gangue content is judged according to the coal flow attribute to control the opening and closing of the coal discharging opening.

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