A control system and method for a mine dual-power rubber-tired scraper rehandler

Abstract

The application provides a mine double-power rubber-tired scraper transfer machine control system and method, relates to the technical field of mine transportation equipment control, and comprises: an anti-explosion diesel engine control system, which is powered by an anti-explosion diesel engine and drives rubber tires to walk; an anti-explosion motor control system, which is powered by two transportation motors and drives a scraper to transport; an auxiliary system, which is used for realizing state detection and protection of the whole machine, including emergency stop, a methane power-off instrument, a remote control system, a video working condition monitoring system, a personnel approach system, an illumination system, an audible and visual alarm system and a hopper valve control system; a double-power switching system, which is used for realizing safe switching of the two powers of the diesel engine and the motor, and the switching operation sequence comprises a walking switching transportation operation sequence and a transportation switching walking operation sequence, and misoperation is prevented through electrical locking. The application can improve the overall operation efficiency of the tunneling working face.

Description

Technical Field

[0001] This invention relates to the field of control technology for mining transportation equipment, and in particular to a control method for a dual-power rubber-wheel scraper conveyor for mining. Background Technology

[0002] The dual-power rubber-wheel scraper transfer machine for mining (hereinafter referred to as rubber-wheel scraper transfer machine) is mainly used as a temporary transfer point in the mine. It connects with the main transport or roadway belt conveyor to transfer materials. It is used in conjunction with coal mine tunneling teams for temporary material transfer in situations such as connecting roadways, functional chambers, and cut-off points.

[0003] Currently, most mines use tracked scraper conveyors for temporary material transfer, which are powered by cables connected to the mine's electrical system. However, tracked conveyors have slow travel speeds, are inconvenient to operate, and have poor mobility, making them unsuitable for frequent site changes, thus affecting the overall efficiency of the tunneling face. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a control method for a mining dual-power rubber-tired scraper transfer machine, which can uniformly unload and transfer the materials to be transferred at temporary transfer points onto a belt conveyor, thereby achieving efficient, fast and flexible transfer and transportation of materials at various temporary transfer points, and thus improving the overall operation efficiency of the tunneling face.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0006] Firstly, a control system for a mining dual-power rubber-wheel scraper conveyor includes:

[0007] The explosion-proof diesel engine control system uses an explosion-proof diesel engine as power to drive rubber wheels for travel, and includes a diesel engine electronic common rail injection device, a diesel locomotive protection device, and a diesel engine power supply device.

[0008] The explosion-proof motor control system uses two transport motors to drive the scraper conveyor, and consists of a power supply unit, a PLC control unit, an execution unit, and a motor protection unit.

[0009] The auxiliary system is used to realize the status detection and protection of the whole machine, including emergency stop, methane power-off device, remote control system, video working condition monitoring system, personnel access system, lighting system, audible and visual alarm system and hopper valve control system;

[0010] The dual-power switching system is used to safely switch between diesel engine and electric motor power. The switching operation sequence includes the sequence of walking to transportation operation and the sequence of transportation to walking operation, and is prevented by electrical interlocking to prevent misoperation.

[0011] Furthermore, the diesel engine electronically controlled common rail injection system includes:

[0012] Sensors are used to monitor engine operating conditions and transmit the real-time collected information to the ECU controller via electrical signals;

[0013] The ECU controller receives and analyzes input information from sensors, processes it, and then sends optimal instructions to the actuators via electrical signals.

[0014] The actuator is used to receive commands from the ECU and control the timing and quantity of fuel injection via mechanical or electrical signals according to the commands.

[0015] The diesel locomotive protection device includes:

[0016] The intrinsically safe display screen is used to communicate with the ECU controller via the CAN bus to display the vehicle status and fault information; the speed sensor, fuel level sensor, hydraulic oil level and temperature sensor and methane sensor are connected to the protection device through sensor lines to monitor in real time and transmit the data to the protection device for display on the screen.

[0017] The diesel engine power supply unit includes:

[0018] An explosion-proof permanent magnet generator is used to connect to a diesel engine via a crankshaft belt. The three-phase AC power generated by the explosion-proof permanent magnet generator is connected to the generator regulator via a cable.

[0019] The generator regulator is used to rectify and regulate the AC power, and then output 24V DC power through a cable to supply the diesel engine control system and other electrical equipment, and to charge the battery power box.

[0020] The power supply unit includes:

[0021] The transformer is used to connect to the 1140V AC power system in the mine and is connected to the switching power supply and intrinsically safe power supply via cables; after conversion between the switching power supply and intrinsically safe power supply, voltage is supplied to the explosion-proof motor via cables.

[0022] The PLC control unit is used to connect to the PLC expansion module via an internal bus; the digital input module collects switch signals, the analog input module collects analog signals, and the communication module performs data interaction; the output point of the PLC control unit is connected to the relay via a cable, and the relay controls the coil of the contactor, thereby controlling the on and off of the motor circuit.

[0023] Furthermore, the sensor includes:

[0024] The crankshaft speed sensor detects the piston's top dead center and crankshaft angle signals and inputs them into the engine ECU to control ignition timing and fuel injection quantity, while also measuring the diesel engine's speed. The camshaft speed sensor detects the camshaft position and angle signals to determine the compression top dead center position of the first cylinder piston. During startup, the ECU identifies the position and stroke of each cylinder piston based on the signals provided by the crankshaft speed sensor and camshaft speed sensor, controlling the fuel injection sequence and ignition sequence for precise fuel injection and ignition control.

[0025] The throttle position sensor is used to transmit the depth signal of the throttle pedal to the ECU to control the intake air volume and fuel injection volume of the diesel engine, thereby realizing the acceleration and deceleration of the vehicle.

[0026] The rail pressure sensor is used to measure the real-time pressure of fuel in the common rail and convert it into a voltage signal to send to the ECU to control the amount and timing of fuel injection.

[0027] The intake air temperature and pressure sensor is used to detect the intake air temperature and pressure of the diesel engine and convert them into voltage signals, which are then input to the ECU as signals for fuel injection correction. The oil temperature and pressure sensor is used to detect the oil condition for lubrication and cooling of the diesel engine.

[0028] Furthermore, the intrinsically safe display communicates with the ECU via the CAN bus to display the vehicle status and fault information; the speed sensor is used for the vehicle's tachometer display; the fuel level sensor is installed on the fuel pump to detect the amount of fuel in the fuel tank; the hydraulic oil level and temperature sensor is installed on the hydraulic oil pump to detect the amount and temperature of hydraulic oil in the hydraulic oil tank; and the methane sensor continuously monitors the methane concentration in the mine and performs emergency power-off protection when the concentration exceeds the limit.

[0029] The diesel engine power supply unit includes: an explosion-proof permanent magnet generator, a generator regulator, and a battery power box; after the diesel engine starts, it drives the explosion-proof permanent magnet generator through the crankshaft belt. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator and converted into 24V DC power to supply the diesel engine control system and other electrical equipment of the whole machine, while charging the battery power box at the same time.

[0030] Furthermore, the power supply unit provides power to the explosion-proof motor and control system. After receiving the start / stop signal, the PLC control unit performs start / stop operations on the motor through the execution unit. The motor protection unit detects the motor operating parameters and provides overload, overcurrent, and phase loss protection to the motor through the PLC control unit.

[0031] The PLC control unit includes: a PLC controller and a PLC expansion module; the PLC expansion module includes a digital input / output module, an analog input module, and a communication module; the digital input module is used to acquire switch signals such as emergency stop, buttons, protectors, and methane power-off devices; the digital output module controls the PLC points to be turned on and off according to the program control logic, connects to intermediate relays to amplify power, and drives contactless devices, lighting, and voice alarm components;

[0032] The analog input module refreshes the ADC conversion value every cycle. It is divided into current and voltage types and is used to acquire signals from voltage and current transmitters, motor winding temperature and pressure sensors.

[0033] Furthermore, it enables safe switching between diesel engine and electric motor power. The switching operation sequence includes the sequence for switching from walking to transportation and the sequence for switching from transportation to walking, and prevents misoperation through electrical interlocking, including:

[0034] Walking to switch to transport operation:

[0035] Turn the cab selector switch to the 0 position to ensure that there is no power input to the electronic control system; connect to the 1140V power supply system, at which point the electronic control system will be powered by 1140V; switch the travel mode to transport mode to start and stop the transport motor.

[0036] Transportation switching walking operation:

[0037] Disconnect the 1140V power supply system; rotate the cab switch to position 2; switch the transport mode to the travel mode and start the diesel engine for travel operation; if the diesel engine is running, it cannot be switched to transport mode, and the ECU power will be automatically cut off in transport mode.

[0038] Furthermore, when the diesel engine is in operating or traveling mode, the dual power supply range is as follows:

[0039] The explosion-proof permanent magnet generator is driven by the crankshaft belt of the diesel engine. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator and then converted into 24V DC power to supply the diesel engine control system, PLC control unit and auxiliary system.

[0040] When the motor is running or in transport mode, the dual-power supply range is:

[0041] The mine's 1140V power system supplies power to two explosion-proof transport motors, the explosion-proof motor control system, and the auxiliary system. The 1140V three-phase AC power supplies the explosion-proof motors. The 1140V three-phase AC power is converted into AC220V, AC127V, AC36V / 24V, DC24V, and DC12V by a transformer and a switching power supply to power the explosion-proof motor control system and the auxiliary system.

[0042] Furthermore, during the operation of the diesel engine:

[0043] The rail pressure sensor measures the real-time pressure of fuel in the common rail and converts it into a voltage signal, which is then sent to the ECU to control the injection quantity and timing, including:

[0044] Define the optimization objective and encode the control parameters as genes of the genetic algorithm. The genes constitute chromosomes, i.e. the solution. The control parameters include fuel injection quantity and fuel injection timing.

[0045] An initial population is randomly generated, which contains multiple chromosomes, each representing a control strategy.

[0046] For each chromosome in the population, the operational performance is simulated using data from the orbital pressure sensor and an engine model; the fitness value of each chromosome is calculated based on the optimization objective.

[0047] Select the corresponding chromosome based on the fitness value for reproduction, perform crossover on the selected chromosome to produce new offspring, perform mutation on the newly generated offspring, replace the original population with the newly generated population, and repeat the iteration until the preset number of iterations is reached, at which point the iteration stops.

[0048] Select the corresponding chromosome from the final population as the final control strategy;

[0049] Based on the final control strategy, the amount and timing of fuel injection are controlled.

[0050] Furthermore, the formula for calculating the fitness value is as follows:

[0051]

[0052] Among them, E f E represents the fuel consumption under the current control strategy. p Indicates the emissions under the current control strategy; N r This represents the engine stability score under the current control strategy; P t Indicates the desired fuel injection quantity; T t Indicates the desired injection timing; P cur Indicates the fuel injection quantity under the current control strategy; T cur This indicates the injection timing under the current control strategy; α1, α2, α3, α4, and α5 are weighting coefficients; where:

[0053]

[0054] Among them, w rpm w L w V and w TThese are the weighting coefficients corresponding to the stability scores of each item; σ rpm σ L σ V and These are the standard deviations corresponding to speed, load, vibration, and temperature fluctuations, respectively.

[0055] Secondly, a control method for a mining dual-power rubber-wheel scraper conveyor is provided. This method is applied to a mining dual-power rubber-wheel scraper conveyor comprising an explosion-proof diesel engine control system, an explosion-proof motor control system, an auxiliary system, and a dual-power switching system. The explosion-proof diesel engine control system uses an explosion-proof diesel engine as power to drive the rubber wheels; the explosion-proof motor control system uses two transport motors as power to drive the scraper conveyor; the auxiliary system is used for overall machine status detection and protection; and the dual-power switching system is used to safely switch between diesel engine and motor power. The method includes the following steps:

[0056] Switching to walking mode, the diesel engine crankshaft belt drives an explosion-proof permanent magnet generator. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator, then converted into 24V DC power to supply the diesel engine control system, PLC control unit, and auxiliary systems. The auxiliary systems include an emergency stop, methane power-off device, personnel access control system, video monitoring system, lighting system, audible and visual alarm system, remote control system, and hopper valve control system. The diesel engine control system controls the diesel engine to drive the rubber wheels for walking. The PLC control unit collects signals from the emergency stop, methane power-off device, and personnel access control system to control the entire machine to stop in an emergency. The PLC control unit collects signals from the operation buttons and remote control system to control the lighting system and hopper valve control system. The PLC control unit communicates with the ECU to obtain diesel engine operating parameters and provides warnings for forward and backward movement through the audible and visual alarm system. The video monitoring system communicates with the PLC control unit to obtain and display the overall machine operating parameters, and simultaneously collects and displays video footage from four cameras on the machine.

[0057] Switching to transport mode, the system supplies power to two explosion-proof transport motors, the explosion-proof motor control system, and auxiliary systems via the mine's 1140V power system. The 1140V three-phase AC power supplies the explosion-proof motors. This 1140V three-phase AC power is then converted via transformers and switching power supplies to AC220V, AC127V, AC36V / 24V, DC24V, and DC12V to power the explosion-proof motor control system and auxiliary systems. The PLC control unit collects signals from operation buttons and the remote control system to control the start / stop of the transport motors, the lighting system, and the audible and visual alarm system. The PLC control unit also collects signals from the emergency stop, methane power-off device, and personnel approach system to control the entire machine's emergency shutdown. The PLC control unit communicates with the video monitoring system to display the machine's operating parameters and simultaneously collects and displays video feeds from four cameras on the machine.

[0058] Furthermore, during the operation of the diesel engine:

[0059] The real-time pressure of fuel in the common rail is measured by a rail pressure sensor and converted into a voltage signal, which is then sent to the ECU.

[0060] In the ECU, the optimization objective is defined, and the control parameters are encoded as genes of a genetic algorithm. These genes constitute chromosomes, which are the solutions. The control parameters include the injection quantity and injection timing.

[0061] An initial population is randomly generated, which contains multiple chromosomes, each representing a control strategy.

[0062] For each chromosome in the population, the operational performance is simulated using data from the rail pressure sensor and the engine model, and the fitness value of each chromosome is calculated based on the optimization objective.

[0063] Chromosomes are selected based on fitness values ​​for reproduction. Crossover is performed on the selected chromosomes to produce new offspring, and mutation is performed on the newly generated offspring.

[0064] Replace the original population with the newly generated population, and repeat the iteration until the preset number of iterations is reached;

[0065] Select the corresponding chromosome from the final population as the final control strategy, and control the fuel injection quantity and timing according to the final control strategy.

[0066] Thirdly, a computing device, comprising:

[0067] One or more processors;

[0068] A storage device for storing one or more programs that, when executed by one or more processors, cause the one or more processors to implement the method.

[0069] Fourthly, a computer-readable storage medium storing a program that, when executed by a processor, implements the method.

[0070] The above-described solutions of the present invention include at least the following beneficial effects.

[0071] This system uses an explosion-proof diesel engine as its power source, ensuring strong power for rubber-wheel travel. The diesel engine's electronically controlled common rail injection system improves fuel injection accuracy and efficiency, helping to reduce fuel consumption and emissions. The diesel locomotive protection device effectively monitors and protects the diesel engine from damage, extending its service life. The diesel engine power supply unit provides a stable and reliable power source for the entire machine, ensuring the normal operation of the control system.

[0072] This system utilizes two transport motors to drive the scraper conveyor, providing powerful transport capabilities. The power supply unit ensures stable power supply to the motors, the PLC control unit implements precise control logic, the execution unit responds quickly to commands, and the motor protection unit effectively prevents motor overload, overcurrent, and phase loss faults, thereby improving the overall safety and reliability of the machine.

[0073] The auxiliary system integrates multiple detection and protection functions, such as emergency stop, methane power-off device, remote control system, and video monitoring system, to achieve comprehensive monitoring and rapid response of the entire machine's status. This not only enables timely detection and handling of potential safety hazards but also improves operator safety and work efficiency. For example, the methane power-off device automatically cuts off the power supply when methane levels exceed the standard, preventing gas explosions; the video monitoring system allows operators to remotely monitor the machine's operating status, facilitating timely adjustments and optimization of workflows.

[0074] This system enables safe switching between diesel and electric power, allowing the machine to flexibly select the most suitable power source in different working scenarios. The clearly defined sequence of travel-to-transport operations and the sequence of transport-to-travel operations, along with the application of electrical interlocks, effectively prevent safety risks caused by misoperation. This dual-power design not only improves the machine's adaptability and flexibility but also enhances its overall safety and stability. Attached Figure Description

[0075] Figure 1 Layout diagram of the control system for a rubber-wheeled scraper conveyor.

[0076] Figure 2 Functional block diagram of explosion-proof diesel engine control system.

[0077] Figure 3 Functional block diagram of explosion-proof motor control system.

[0078] Figure 4 Dual-power switching strategy. Detailed Implementation

[0079] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0080] An embodiment of the present invention provides a control system for a mining dual-power rubber-wheel scraper conveyor, comprising:

[0081] The explosion-proof diesel engine control system uses an explosion-proof diesel engine as power to drive rubber wheels for travel, and includes a diesel engine electronic common rail injection device, a diesel locomotive protection device, and a diesel engine power supply device.

[0082] The explosion-proof motor control system uses two transport motors to drive the scraper conveyor, and consists of a power supply unit, a PLC control unit, an execution unit, and a motor protection unit.

[0083] The auxiliary system is used to realize the status detection and protection of the whole machine, including emergency stop, methane power-off device, remote control system, video working condition monitoring system, personnel access system, lighting system, audible and visual alarm system and hopper valve control system;

[0084] The dual-power switching system is used to safely switch between diesel engine and electric motor power. The switching operation sequence includes the sequence of walking to transportation operation and the sequence of transportation to walking operation, and is prevented by electrical interlocking to prevent misoperation.

[0085] In this embodiment of the invention, the system combines two power sources: an explosion-proof diesel engine and an electric motor, enabling the scraper conveyor to maintain efficient operation in various working environments. Whether long-distance movement or high-power material transport is required, the system can meet the needs by switching between different power sources, greatly enhancing the machine's flexibility and adaptability. The independent design of the explosion-proof diesel engine and electric motor control systems ensures the stability and safety of the power system. Simultaneously, safety facilities in the auxiliary system, such as a methane power-off device, emergency stop device, and audible and visual alarm system, can take timely measures in emergencies to prevent accidents and improve workplace safety. The application of a PLC control unit and remote control system makes operation more intelligent and automated. Operators can remotely control the machine, reducing the difficulty and risk of manual operation. At the same time, the video monitoring system can monitor the machine's working status in real time, facilitating timely adjustments and optimization of the workflow. The application of the diesel engine's electronic common rail injection device improves fuel injection efficiency and accuracy, helping to reduce fuel consumption, reduce harmful gas emissions, and make the system more environmentally friendly. Various components in the auxiliary system, such as the personnel access system, lighting system, audible and visual alarm system, and hopper valve control system, together provide comprehensive status detection and protection functions for the entire machine. These systems can promptly detect potential safety hazards and alert operators to take appropriate measures through audible and visual alarms.

[0086] In a preferred embodiment of the present invention, the diesel engine electronically controlled common rail injection device includes:

[0087] Sensors are used to monitor engine operating conditions and transmit the real-time collected information to the ECU controller via electrical signals;

[0088] The ECU controller receives and analyzes input information from sensors, processes it, and then sends optimal instructions to the actuators via electrical signals.

[0089] An actuator is used to receive commands from the ECU and control the injection timing and quantity of fuel via mechanical or electrical signals according to the commands; the diesel locomotive protection device includes:

[0090] The intrinsically safe display screen is used to communicate with the ECU controller via the CAN bus to display the vehicle status and fault information; the speed sensor, fuel level sensor, hydraulic oil level and temperature sensor and methane sensor are connected to the protection device through sensor lines to monitor in real time and transmit the data to the protection device for display on the screen.

[0091] The diesel engine power supply unit includes:

[0092] An explosion-proof permanent magnet generator is used to connect to a diesel engine via a crankshaft belt. The three-phase AC power generated by the explosion-proof permanent magnet generator is connected to the generator regulator via a cable.

[0093] The generator regulator is used to rectify and regulate the AC power, and then output 24V DC power through a cable to supply the diesel engine control system and other electrical equipment, and to charge the battery power box.

[0094] In this embodiment of the invention, the diesel engine electronic common rail injection device monitors the engine operating condition in real time through sensors and transmits this data to the ECU controller. After precise calculation, the ECU controller sends optimal commands to the actuators, thereby achieving precise control of the injection timing and injection quantity. This precise control not only improves fuel utilization efficiency but also reduces unnecessary fuel consumption and exhaust emissions, enabling the engine to maintain efficient operation under various conditions. The diesel locomotive protection device monitors the vehicle's status and key parameters in real time through an intrinsically safe display screen and various sensors. These sensors include speed sensors, fuel level sensors, hydraulic oil level and temperature sensors, and methane sensors, which can promptly detect potential faults and safety hazards and provide operators with intuitive fault information and vehicle status through the display screen, thereby helping operators take timely measures to prevent the fault from escalating or causing a safety accident. The explosion-proof permanent magnet generator in the diesel engine power unit can stably generate three-phase AC power, which is rectified and regulated by the generator regulator to ultimately output a stable 24V DC power. This design not only ensures a stable power supply to the diesel engine control system and other electrical equipment, but also charges the battery pack, thus guaranteeing a stable power supply to the diesel engine starting system and other electrical devices when the generator stops generating electricity. Through precise control of the electronic common rail injection system, fuel consumption and harmful emissions can be significantly reduced, meeting modern environmental protection requirements. At the same time, because each system adopts a highly reliable and long-life design, overall maintenance costs and downtime can be reduced, improving production efficiency.

[0095] In a preferred embodiment of the present invention, the power supply unit includes:

[0096] The transformer is used to connect to the 1140V AC power system in the mine and is connected to the switching power supply and intrinsically safe power supply via cables; after conversion between the switching power supply and intrinsically safe power supply, voltage is supplied to the explosion-proof motor via cables.

[0097] The PLC controller is used to connect to the PLC expansion module via an internal bus; the digital input module collects switch signals, the analog input module collects analog signals, and the communication module performs data interaction; the output point of the PLC control unit is connected to the relay via a cable, and the relay controls the coil of the contactor, thereby controlling the on and off of the motor circuit.

[0098] The sensor includes:

[0099] The crankshaft speed sensor detects the piston's top dead center and crankshaft angle signals and inputs them into the engine ECU to control ignition timing and fuel injection quantity, while also measuring the diesel engine's speed. The camshaft speed sensor detects the camshaft position and angle signals to determine the compression top dead center position of the first cylinder piston. During startup, the ECU identifies the position and stroke of each cylinder piston based on the signals provided by the crankshaft speed sensor and camshaft speed sensor, controlling the fuel injection sequence and ignition sequence for precise fuel injection and ignition control.

[0100] The throttle position sensor is used to transmit the depth signal of the throttle pedal to the ECU to control the intake air volume and fuel injection volume of the diesel engine, thereby realizing the acceleration and deceleration of the vehicle.

[0101] The rail pressure sensor is used to measure the real-time pressure of fuel in the common rail and convert it into a voltage signal to send to the ECU to control the amount and timing of fuel injection.

[0102] The intake air temperature and pressure sensor is used to detect the intake air temperature and pressure of the diesel engine and convert them into voltage signals, which are then input to the ECU as signals for fuel injection correction. The oil temperature and pressure sensor is used to detect the oil condition for lubrication and cooling of the diesel engine.

[0103] In this embodiment of the invention, the power supply unit is connected to the mine's 1140V AC power system via a transformer, and after conversion between a switching power supply and an intrinsically safe power supply, provides a stable and reliable voltage to the explosion-proof motor. This design ensures that the motor can operate stably even in the harsh mine environment, improving the overall reliability and efficiency of the machine. The PLC controller is connected to the PLC expansion module via an internal bus, realizing the acquisition of switch signals and analog signals, as well as data interaction. This intelligent control logic enables the machine to automatically adjust according to the real-time working status, improving the automation level and ease of operation. The application of crankshaft speed sensors and camshaft speed sensors allows the ECU to accurately identify the position and stroke of each cylinder piston, thereby performing precise fuel injection and ignition control. This not only improves the engine's combustion efficiency but also reduces exhaust emissions, meeting environmental protection requirements. The application of throttle position sensors, rail pressure sensors, intake air temperature and pressure sensors, and oil temperature and pressure sensors provides the ECU with rich real-time data, enabling it to adjust the fuel injection quantity and timing in real time according to the vehicle's working status and external environment. This real-time status monitoring and adjustment mechanism ensures that the machine maintains optimal working condition under various operating conditions.

[0104] In a preferred embodiment of the present invention, the intrinsically safe display screen communicates with the ECU via a CAN bus to display the vehicle status and fault information; the speed sensor is used for the vehicle tachometer display; the fuel level sensor is installed on the fuel pump to detect the amount of fuel in the fuel tank; the hydraulic oil level and temperature sensor is installed on the hydraulic oil pump to detect the amount and temperature of hydraulic oil in the hydraulic oil tank; and the methane sensor continuously monitors the methane concentration in the mine and performs emergency power-off protection when the concentration exceeds the limit.

[0105] The diesel engine power supply unit includes: an explosion-proof permanent magnet generator, a generator regulator, and a battery power box; after the diesel engine starts, it drives the explosion-proof permanent magnet generator through the crankshaft belt. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator and converted into 24V DC power to supply the diesel engine control system and other electrical equipment of the whole machine, while charging the battery power box at the same time.

[0106] In this embodiment of the invention, the intrinsically safe display screen communicates with the ECU via a CAN bus, enabling real-time display of the vehicle's status and fault information. This design allows operators to intuitively understand the machine's operating status, and in the event of a fault, can quickly locate and take measures, thereby greatly improving the efficiency and accuracy of fault handling. The application of speed sensors, fuel level sensors, hydraulic oil level and temperature sensors, and methane sensors enables comprehensive monitoring of key vehicle parameters. These sensors can detect and feedback various data in real time, ensuring the machine operates within a safe range. In particular, the methane sensor can continuously monitor the methane concentration in the mine; once the concentration exceeds the limit, it immediately triggers emergency power-off protection, effectively preventing safety accidents caused by excessive methane levels. The diesel engine power supply unit configuration, including an explosion-proof permanent magnet generator, a generator regulator, and a battery power supply box, ensures a stable and reliable power supply for the entire machine. The explosion-proof permanent magnet generator can continuously generate three-phase AC power after the diesel engine starts, which, after rectification and regulation by the generator regulator, is converted into a stable 24V DC power to supply various control systems and electrical equipment. At the same time, the device can also charge the battery power box for emergencies, further enhancing the overall reliability and emergency response capabilities of the machine.

[0107] In a preferred embodiment of the present invention, the power supply unit provides power to the explosion-proof motor and the control system. After receiving the start-stop signal, the PLC control unit performs start-stop operation on the motor through the execution unit. The motor protection unit detects the motor operating parameters and performs overload, overcurrent and phase loss protection on the motor through the PLC control unit.

[0108] The PLC control unit includes: a PLC controller and a PLC expansion module; the PLC expansion module includes a digital input / output module, an analog input module, and a communication module; the digital input module is used to acquire switch signals such as emergency stop, buttons, protectors, and methane power-off devices; the digital output module controls the PLC points to be turned on and off according to the program control logic, connects to intermediate relays to amplify power, and drives contactless devices, lighting, and voice alarm components;

[0109] The analog input module refreshes the ADC conversion value every cycle. It is divided into current and voltage types and is used to acquire signals from voltage and current transmitters, motor winding temperature and pressure sensors.

[0110] In this embodiment of the invention, the power supply unit provides a stable and reliable power supply to the explosion-proof motor and the entire control system, which is fundamental to ensuring normal system operation and reducing malfunctions. A stable power supply helps extend the service life of the equipment and improve system reliability. The PLC control unit can precisely control the start and stop of the motor by receiving start / stop signals. This intelligent control method simplifies the operation process, improves work efficiency, and reduces the possibility of human error. The motor protection unit monitors the motor's operating parameters in real time, such as current, voltage, and temperature, and provides overload, overcurrent, and phase loss protection to the motor through the PLC control unit. This comprehensive protection mechanism helps to promptly detect and handle potential safety hazards, prevent motor damage due to abnormal conditions, and thus ensure the safe operation of the motor. The digital input / output modules and analog input modules in the PLC expansion module can flexibly acquire and process various signals. The digital input module can acquire switch signals such as emergency stop, buttons, protectors, and methane power-off devices, while the analog input module can acquire analog signals such as voltage and current transmitters, motor winding temperature, and pressure sensors. This flexible signal acquisition and processing function enables the system to adapt to various complex working environments and make accurate responses.

[0111] In a preferred embodiment of the present invention, safe switching between diesel engine and electric motor power is achieved. The switching operation sequence includes a walking-to-transport operation sequence and a transport-to-walk operation sequence, and electrical interlocking is used to prevent misoperation, including:

[0112] Walking to switch to transport operation:

[0113] Turn the cab selector switch to the 0 position to ensure that there is no power input to the electronic control system; connect to the 1140V power supply system, at which point the electronic control system will be powered by 1140V; switch the travel mode to the transport mode, that is, perform the start and stop operation of the transport motor;

[0114] Transportation switching walking operation:

[0115] Disconnect the 1140V power supply system; rotate the cab selector switch to position 2; switch the transport mode to the travel mode and start the diesel engine for travel operation; if the diesel engine is running, it cannot be switched to transport mode, and the ECU power will be automatically cut off in transport mode;

[0116] In a preferred embodiment of the present invention, when the diesel engine is in operation or traveling mode, the dual power supply range is as follows:

[0117] An explosion-proof permanent magnet generator is driven by a diesel engine crankshaft belt. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator and then converted into 24V DC power to supply the diesel engine control system, PLC control unit and auxiliary system.

[0118] In this embodiment of the invention, the clear switching sequence and electrical interlocking design effectively prevent misoperation. This design ensures that power switching can only be performed under safe conditions, thereby greatly reducing the safety risks caused by misoperation. The dual power supply range and detailed control system design enable the machine to smoothly switch between different power sources, ensuring system stability and reliability. Whether in walking or transport mode, the system provides continuous and stable power output. Clear switching steps and an intelligent control system reduce downtime and waiting time during operation, thereby improving work efficiency. Operators can complete power switching more quickly and continue to the next step of work. The tight integration of the PLC control unit with various systems enables comprehensive monitoring of the machine's operating status. Simultaneously, through the audible and visual alarm system and video monitoring system, operators can understand the machine's operating status in real time and receive timely warnings when potential problems arise, allowing for appropriate measures to be taken. The clear power switching logic and electrical control system design also simplify the equipment maintenance process. Maintenance personnel can more easily identify and resolve problems, reducing downtime and improving equipment utilization.

[0119] In a preferred embodiment of the present invention, when the motor is running or in transport mode, the dual power supply range is:

[0120] The mine's 1140V power system supplies power to two explosion-proof transport motors, the explosion-proof motor control system, and the auxiliary system. The 1140V three-phase AC power supplies the explosion-proof motors. The 1140V three-phase AC power is converted into AC220V, AC127V, AC36V / 24V, DC24V, and DC12V by a transformer and a switching power supply to power the explosion-proof motor control system and the auxiliary system.

[0121] In this embodiment of the invention, the 1140V power system of the mine is directly used to power the explosion-proof motor and control system of the transport vehicle, ensuring an efficient and stable energy supply. This design reduces energy conversion losses and improves energy utilization efficiency. Through transformers and switching power supplies, the 1140V three-phase AC power is converted into multiple voltage levels to meet the different power requirements of the explosion-proof motor control system and auxiliary systems. This design enhances the flexibility and adaptability of the system. The PLC control unit can collect various signals and intelligently control the start and stop of the transport motor, the lighting system, and the audible and visual alarm system based on these signals. This intelligent control improves the convenience and accuracy of operation. The PLC control unit can collect key safety signals such as emergency stop, methane power failure, and personnel approach system in real time, and control the entire machine to stop urgently when necessary. This design significantly improves the safety performance of the equipment and protects the lives of operators. Through communication with the video monitoring system, the PLC control unit can display the operating parameters of the entire machine and collect and display video images from the camera on the machine in real time. This provides operators with comprehensive equipment status information, facilitating timely detection and problem solving. The clear power system and control system design simplifies the equipment maintenance and repair process. Maintenance personnel can more easily identify and repair faults, reducing downtime and maintenance costs.

[0122] In a preferred embodiment of the present invention, the rail pressure sensor is used to measure the real-time pressure of fuel in the common rail and convert it into a voltage signal to be sent to the ECU to control the fuel injection quantity and injection timing, including:

[0123] Define the optimization objective and encode the control parameters as genes of the genetic algorithm. The genes constitute chromosomes, i.e. the solution. The control parameters include fuel injection quantity and fuel injection timing.

[0124] An initial population is randomly generated, which contains multiple chromosomes, each representing a control strategy.

[0125] For each chromosome in the population, the operational performance is simulated using data from the orbital pressure sensor and an engine model; the fitness value of each chromosome is calculated based on the optimization objective.

[0126] Select the corresponding chromosome based on the fitness value for reproduction, perform crossover on the selected chromosome to produce new offspring, perform mutation on the newly generated offspring, replace the original population with the newly generated population, and repeat the iteration until the preset number of iterations is reached, at which point the iteration stops.

[0127] Select the corresponding chromosome from the final population as the final control strategy;

[0128] Based on the final control strategy, the amount and timing of fuel injection are controlled.

[0129] In this embodiment of the invention, by measuring the fuel pressure in the common rail in real time using a rail pressure sensor, the fuel injection quantity and timing can be controlled more precisely, thereby improving engine combustion efficiency and performance. The genetic algorithm, through iterative optimization, can find the optimal combination of fuel injection quantity and timing, resulting in more economical fuel consumption and reduced operating costs. Precise control of the fuel injection process helps reduce incomplete combustion and excessive fuel consumption, thereby reducing harmful gas emissions and making the vehicle more environmentally friendly. The optimized fuel injection control strategy can improve engine response speed, making vehicle acceleration faster and smoother. Reasonable fuel injection control can reduce engine wear and overheating, extending engine life. The genetic algorithm can adaptively adjust the control strategy to adapt to different operating conditions and environmental conditions, ensuring that the engine always operates in optimal condition. By integrating the rail pressure sensor and the genetic algorithm, intelligent management of the engine fuel injection system is achieved, improving the overall vehicle intelligence level.

[0130] In a preferred embodiment of the present invention, the formula for calculating the fitness value is as follows:

[0131]

[0132] Among them, E f E represents the fuel consumption under the current control strategy. p Indicates the emissions under the current control strategy; N r This represents the engine stability score under the current control strategy; P t Indicates the desired fuel injection quantity; T t Indicates the desired injection timing; P cur Indicates the fuel injection quantity under the current control strategy; T cur This indicates the injection timing under the current control strategy; α1, α2, α3, α4, and α5 are weighting coefficients; where:

[0133]

[0134] Among them, w rpm w L w V and w T These are the weighting coefficients corresponding to the stability scores of each item; σ rpm σ L σ V and These are the standard deviations corresponding to speed, load, vibration, and temperature fluctuations, respectively.

[0135] In this embodiment of the invention, the fitness value formula encompasses multiple key indicators of engine operation, such as fuel consumption, emissions, and stability, ensuring that the optimization process comprehensively considers these factors, thereby improving the overall performance of the engine. This is achieved by setting the desired fuel injection quantity and injection timing P.t and T t The formula guides the genetic algorithm towards a predetermined goal, making the control strategy more aligned with practical needs. The settings of weight coefficients α1, α2, α3, α4, and α5 allow for adjusting the priority of various indicators according to different application scenarios or performance requirements, making the optimization process more flexible. r The calculations take into account multiple stability-related factors such as engine speed, load, vibration, and temperature fluctuations, which helps improve the engine's operational stability under various operating conditions. By calculating the deviation between the fuel injection quantity and injection timing under the current control strategy and the desired values, the formula can precisely guide the genetic algorithm to fine-tune the control parameters, thereby achieving more precise fuel injection control.

[0136] A control method for a mining dual-power rubber-wheel scraper conveyor is disclosed. This method is applied to a mining dual-power rubber-wheel scraper conveyor comprising an explosion-proof diesel engine control system, an explosion-proof motor control system, an auxiliary system, and a dual-power switching system. The explosion-proof diesel engine control system uses an explosion-proof diesel engine as power to drive the rubber wheels; the explosion-proof motor control system uses two transport motors as power to drive the scraper conveyor; the auxiliary system is used for overall machine status detection and protection; and the dual-power switching system is used to safely switch between diesel engine and motor power. The method includes the following steps:

[0137] Switching to walking mode, the diesel engine crankshaft belt drives an explosion-proof permanent magnet generator. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator, then converted into 24V DC power to supply the diesel engine control system, PLC control unit, and auxiliary systems. The auxiliary systems include an emergency stop, methane power-off device, personnel access control system, video monitoring system, lighting system, audible and visual alarm system, remote control system, and hopper valve control system. The diesel engine control system controls the diesel engine to drive the rubber wheels for walking. The PLC control unit collects signals from the emergency stop, methane power-off device, and personnel access control system to control the entire machine to stop in an emergency. The PLC control unit collects signals from the operation buttons and remote control system to control the lighting system and hopper valve control system. The PLC control unit communicates with the ECU to obtain diesel engine operating parameters and provides warnings for forward and backward movement through the audible and visual alarm system. The video monitoring system communicates with the PLC control unit to obtain and display the overall machine operating parameters, and simultaneously collects and displays video footage from four cameras on the machine.

[0138] Switching to transport mode, the system supplies power to two explosion-proof transport motors, the explosion-proof motor control system, and auxiliary systems via the mine's 1140V power system. The 1140V three-phase AC power supplies the explosion-proof motors. This 1140V three-phase AC power is then converted via transformers and switching power supplies to AC220V, AC127V, AC36V / 24V, DC24V, and DC12V to power the explosion-proof motor control system and auxiliary systems. The PLC control unit collects signals from operation buttons and the remote control system to control the start / stop of the transport motors, the lighting system, and the audible and visual alarm system. The PLC control unit also collects signals from the emergency stop, methane power-off device, and personnel approach system to control the entire machine's emergency shutdown. The PLC control unit communicates with the video monitoring system to display the machine's operating parameters and simultaneously collects and displays video feeds from four cameras on the machine.

[0139] Furthermore, during the operation of the diesel engine:

[0140] The real-time pressure of fuel in the common rail is measured by a rail pressure sensor and converted into a voltage signal, which is then sent to the ECU.

[0141] In the ECU, the optimization objective is defined, and the control parameters are encoded as genes of a genetic algorithm. These genes constitute chromosomes, which are the solutions. The control parameters include the injection quantity and injection timing.

[0142] An initial population is randomly generated, which contains multiple chromosomes, each representing a control strategy.

[0143] For each chromosome in the population, the operational performance is simulated using data from the rail pressure sensor and the engine model, and the fitness value of each chromosome is calculated based on the optimization objective.

[0144] Chromosomes are selected based on fitness values ​​for reproduction. Crossover is performed on the selected chromosomes to produce new offspring, and mutation is performed on the newly generated offspring.

[0145] Replace the original population with the newly generated population, and repeat the iteration until the preset number of iterations is reached;

[0146] Select the corresponding chromosome from the final population as the final control strategy, and control the fuel injection quantity and timing according to the final control strategy.

[0147] The rubber-wheeled scraper transfer machine of this invention adopts dual-power drive, using a diesel engine as the driving force and rubber wheels for movement. After moving to the required temporary material transfer point, it connects with the main conveyor or the roadway belt conveyor, and the cable connects to the motor for power. It can evenly unload and transfer the materials to be transferred at the temporary transfer point onto the belt conveyor, realizing efficient, fast, and flexible transfer and transportation of materials at various temporary transfer points, thereby improving the overall operation efficiency of the tunneling face.

[0148] 1. Overall machine control system.

[0149] The overall control system includes an explosion-proof diesel engine control system, an explosion-proof motor control system, auxiliary systems, and a dual-power switching system. The explosion-proof diesel engine control system uses an explosion-proof diesel engine to drive the rubber wheels for movement; the explosion-proof motor control system uses two transport motors to drive the scraper conveyor; the auxiliary system realizes the status detection and protection of the entire machine; and the dual-power switching strategy is used for the safe switching between diesel engine and motor power.

[0150] 2. The explosion-proof diesel engine control system mainly includes: diesel engine electronic common rail injection device, diesel locomotive protection device, and diesel engine power supply device.

[0151] The electronic common rail injection system for diesel engines includes sensors, an ECU controller, and actuators. Its function is to electronically control the diesel engine's fuel injection system, enabling real-time adjustments to the injection quantity and timing under different operating conditions. Sensors monitor engine operating conditions and transmit the collected information to the ECU controller. The ECU controller receives and analyzes the input information, processes it, and sends optimal commands to the actuators. The actuators receive the ECU commands and control the injection timing and quantity accordingly, ensuring the diesel engine operates at its best.

[0152] The sensors include: crankshaft speed sensor, camshaft speed sensor, throttle position sensor, rail pressure sensor, intake air temperature and pressure sensor, and oil temperature and pressure sensor. The crankshaft speed sensor, also known as the diesel engine speed sensor, is one of the most important sensors in the diesel engine electronic control system. It detects the piston's top dead center and crankshaft angle signals and inputs them to the engine ECU for controlling ignition timing and fuel injection quantity. It also measures the diesel engine's speed. The camshaft speed sensor detects the camshaft position and angle signals to determine the compression top dead center position of the first cylinder piston. During startup, the ECU uses signals from the crankshaft and camshaft speed sensors to identify the position and stroke of each cylinder piston, controlling the fuel injection sequence and ignition sequence for precise fuel injection and ignition control. The throttle position sensor transmits the accelerator pedal depth signal to the ECU, thereby controlling the diesel engine's intake air volume and fuel injection quantity to achieve vehicle acceleration and deceleration. The rail pressure sensor accurately and quickly measures the real-time pressure of the fuel in the common rail and converts it into a voltage signal, sending it to the ECU for precise control of fuel injection quantity and timing. The intake air temperature and pressure sensor detects the intake air temperature and pressure of the diesel engine and converts them into voltage signals, which are then input to the ECU as signals for fuel injection correction. The oil temperature and pressure sensor detects the oil condition to ensure its lubrication and cooling function for the diesel engine.

[0153] Actuators include: injector solenoid valves, fuel flow metering solenoid valves, etc. Among them, the injector solenoid valve is used to precisely control the injection timing and injection quantity, and the fuel flow metering solenoid valve is used to control the fuel supply to the high-pressure fuel pump to maintain the required fuel rail pressure.

[0154] The diesel locomotive protection devices include: an intrinsically safe display screen, a speed sensor, a fuel level sensor, a hydraulic fluid level and temperature sensor, and a methane sensor. The intrinsically safe display screen communicates with the ECU via a CAN bus to display vehicle status and fault information. The speed sensor is used for vehicle tachometer display. The fuel level sensor is installed on the fuel pump to detect the amount of fuel in the fuel tank. The hydraulic fluid level and temperature sensor is installed on the hydraulic pump to detect the amount and temperature of hydraulic fluid in the hydraulic tank. The methane sensor continuously monitors the methane concentration in the mine and provides emergency power-off protection when the concentration exceeds the limit.

[0155] The diesel engine power supply unit includes: an explosion-proof permanent magnet generator, a generator regulator, and a battery power supply box. After the diesel engine starts, it drives the explosion-proof permanent magnet generator via the crankshaft belt. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator, and then converted into 24V DC power to supply the diesel engine control system and other electrical equipment of the whole machine. At the same time, it charges the battery power supply box, and drives the scraper conveyor with the explosion-proof motor as the power source.

[0156] 3. The explosion-proof motor control system mainly includes: a power supply unit, a PLC control unit, an execution unit, and a motor protection unit. The power supply unit provides power to the explosion-proof motor and control system. After receiving start / stop signals, the PLC control unit performs start / stop operations on the motor through the execution unit. The motor protection unit detects motor operating parameters and provides overload, overcurrent, and phase loss protection to the motor through the PLC control unit. The explosion-proof motor control system is the core of the entire electrical system. It not only performs various protection and communication functions for the motor but also implements corresponding control functions. By calculating and processing the system's collected parameters, it judges the actual operating status of the motor. If a fault occurs, it issues a corresponding trip command based on the fault type.

[0157] The power supply unit includes a transformer, a switching power supply, and an intrinsically safe power supply. The power supply unit connects to the mine's 1140V AC power system to provide power to the explosion-proof motor. At the same time, the transformer, switching power supply, and intrinsically safe power supply convert the 1140V AC to various voltage levels required by the control system, including AC220V, AC127V, AC36V / 24V, DC24V, and DC12V.

[0158] The PLC control unit includes a PLC controller and PLC expansion modules. The PLC controller handles the overall system control logic, while the expansion modules include digital input / output modules, analog input modules, and communication modules. Digital input modules acquire switching signals from emergency stops, buttons, protectors, and methane power-off devices. Digital output modules control the PLC's on / off states according to the program's control logic, amplifying power via intermediate relays to drive various components such as contactors, lights, and voice alarms. Analog input modules refresh the ADC conversion values ​​each cycle, offering current and voltage inputs for acquiring signals from voltage and current transmitters, motor winding temperature sensors, and pressure sensors. The communication modules include Ethernet, RS485, and CAN bus ports for data exchange with the display system and diesel engine control system.

[0159] The execution unit includes a circuit breaker, a contactor, and a relay. The circuit breaker is used to stop and supply power to the entire explosion-proof motor control system. The connection and disconnection of the power supply to the motor circuit are achieved by the PLC output point driving the relay, and the relay controls the contactor coil.

[0160] The motor protection unit includes: current / voltage transmitter, leakage current interlock protection, AC127V and AC36V leakage current monitoring, motor overheat protection, and motor winding temperature detection. The PLC module or communication module acquires the current transmitter signal, and the controller software calculates and determines faults such as overcurrent, overload, and phase loss that occur during motor operation. In response, the PLC output point disconnects, the relay de-energizes, the vacuum contactor coil de-energizes, the contactor disconnects, and the motor circuit stops operating.

[0161] 4. The auxiliary system includes:

[0162] Emergency stop, methane power-off device, remote control system, video monitoring system, personnel access system, lighting system, audible and visual alarm system, hopper valve control system, etc.

[0163] 5. Dual-power switching strategy, specifically including:

[0164] Dual-power switching operation sequence:

[0165] Walking to switch the transport operation sequence:

[0166] 1) Rotate the cab switch to the 0 position (at this time, the diesel engine battery output is turned off and the ECU power is cut off) to ensure that there is no power input to the electronic control system;

[0167] 2) Connect to a 1140V power supply system; at this time, the electrical control system is powered by 1140V.

[0168] 3) Switch the walking mode to the transport mode to start and stop the transport motor.

[0169] Transportation switching and walking operation sequence:

[0170] 1) Disconnect the 1140V power supply system;

[0171] 2) Rotate the cab switch to position 2 (at this time, the diesel engine battery output is normal, the ECU power is on, and the electronic control system is powered by the diesel engine battery);

[0172] 3) Switch the transport mode to walking mode and start the diesel engine to perform walking operations;

[0173] Electrical interlock: To prevent accidental operation, the diesel engine cannot be switched to transport mode while it is running. In transport mode, the ECU power is automatically cut off.

[0174] Dual power supply range:

[0175] In diesel engine operation and travel mode: The diesel engine crankshaft belt drives an explosion-proof permanent magnet generator. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator, then converted into 24V DC power to supply the diesel engine control system, PLC control unit, and auxiliary systems. The auxiliary systems include emergency stop, methane power-off device, personnel approach system, video monitoring system, lighting system, audible and visual alarm system, remote control system, and hopper valve control system. At this time, the diesel engine control system controls the diesel engine to drive the rubber wheels for travel; the PLC control unit collects signals from the emergency stop, methane power-off device, and personnel approach system to control the entire machine to stop urgently; the PLC control unit collects signals from the operation buttons and remote control system to control the lighting system and hopper valve control system; the PLC control unit communicates with the ECU to obtain diesel engine operating parameters and provides warnings for forward and backward movement through the audible and visual alarm system; the video monitoring system communicates with the PLC control unit to obtain and display the overall machine operating parameters, and simultaneously collects and displays video footage from four cameras on the machine to help the operator understand the overall situation of the tunnel.

[0176] In motor operation and transportation mode: The mine's 1140V power system supplies power to two explosion-proof transport motors, the explosion-proof motor control system, and auxiliary systems. Specifically, 1140V three-phase AC power supplies the explosion-proof motors; this 1140V three-phase AC power is converted by transformers and switching power supplies to AC220V, AC127V, AC36V / 24V, DC24V, and DC12V to power the explosion-proof motor control system and auxiliary systems. At this time, the PLC control unit collects signals from operation buttons and the remote control system to control the start / stop of the transport motors, the lighting system, and the audible and visual alarm system; the PLC control unit also collects signals from the emergency stop, methane power-off device, and personnel approach system to control the entire machine's emergency shutdown; the PLC control unit communicates with the video monitoring system to display the machine's operating parameters, and simultaneously collects and displays video footage from four cameras on the machine to help the driver understand the overall situation in the tunnel.

[0177] It should be noted that this system is a system corresponding to the above method. All implementation methods in the above method embodiments are applicable to this embodiment and can achieve the same technical effect.

[0178] Embodiments of the present invention also provide a computing device, including: a processor and a memory storing a computer program, wherein the computer program, when executed by the processor, performs the method described above. All implementations in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

[0179] Embodiments of the present invention also provide a computer-readable storage medium storing instructions that, when executed on a computer, cause the computer to perform the method described above. All implementations in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

Claims

1. A control system for a mining dual-power rubber-wheel scraper conveyor, characterized in that, include: The explosion-proof diesel engine control system uses an explosion-proof diesel engine as power to drive rubber wheels for travel, and includes a diesel engine electronic common rail injection device, a diesel locomotive protection device, and a diesel engine power supply device. The diesel engine electronic common rail injection system includes: a sensor for monitoring engine operating conditions and transmitting the real-time collected information to the ECU controller via an electrical signal; The explosion-proof motor control system uses two transport motors to drive the scraper conveyor, and consists of a power supply unit, a PLC control unit, an execution unit, and a motor protection unit. The auxiliary system is used to realize the status detection and protection of the whole machine, including emergency stop, methane power-off device, remote control system, video working condition monitoring system, personnel access system, lighting system, audible and visual alarm system and hopper valve control system; The dual-power switching system is used to safely switch between diesel engine and electric motor power. The switching operation sequence includes a travel-to-transport operation sequence and a transport-to-travel operation sequence, and is prevented from being misoperated by electrical interlocking. The sensors include: The crankshaft speed sensor detects the piston's top dead center and crankshaft angle signals and inputs them into the engine ECU to control ignition timing and fuel injection quantity, while also measuring the diesel engine's speed. The camshaft speed sensor detects the camshaft position and angle signals to determine the compression top dead center position of the first cylinder piston. During startup, the ECU identifies the position and stroke of each cylinder piston based on the signals provided by the crankshaft speed sensor and camshaft speed sensor, controlling the fuel injection sequence and ignition sequence for precise fuel injection and ignition control. The throttle position sensor is used to transmit the depth signal of the throttle pedal to the ECU to control the intake air volume and fuel injection volume of the diesel engine, thereby realizing the acceleration and deceleration of the vehicle. The rail pressure sensor measures the real-time pressure of fuel in the common rail and converts it into a voltage signal, which is then sent to the ECU to control the injection quantity and timing. This process includes: defining an optimization objective; encoding control parameters as genes in a genetic algorithm, where genes constitute chromosomes, representing solutions; randomly generating an initial population containing multiple chromosomes, each representing a control strategy; simulating the operating effect for each chromosome in the population using rail pressure sensor data and an engine model; and calculating the fitness value for each chromosome based on the optimization objective. The fitness value is calculated using the following formula: ； in, This indicates the fuel consumption under the current control strategy; This indicates the emissions under the current control strategy; This indicates the engine stability score under the current control strategy; Indicates the desired amount of fuel injected; Indicates the desired fuel injection timing; This indicates the amount of fuel injected under the current control strategy; Indicates the injection timing under the current control strategy; , , , and These are the weighting coefficients; where: ； in, , , and These are the weighting coefficients corresponding to each stability score; , , and These are the standard deviations corresponding to speed, load, vibration, and temperature fluctuations, respectively. The intake air temperature and pressure sensor is used to detect the intake air temperature and pressure of the diesel engine and convert them into voltage signals, which are then input to the ECU as signals for fuel injection correction. The oil temperature and pressure sensor is used to detect the oil condition for lubrication and cooling of the diesel engine.

2. The control system for the mining dual-power rubber-wheel scraper conveyor according to claim 1, characterized in that, A diesel engine electronically controlled common rail injection system includes: The ECU controller receives and analyzes input information from sensors, processes it, and then sends optimal commands to the actuators via electrical signals. The actuator is used to receive commands from the ECU and control the timing and quantity of fuel injection via mechanical or electrical signals according to the commands. The diesel locomotive protection device includes: The intrinsically safe display screen is used to communicate with the ECU controller via the CAN bus to display the vehicle status and fault information; the speed sensor, fuel level sensor, hydraulic oil level and temperature sensor and methane sensor are connected to the protection device through sensor lines to monitor in real time and transmit the data to the protection device for display on the screen. The diesel engine power supply unit includes: An explosion-proof permanent magnet generator is used to connect to a diesel engine via a crankshaft belt. The three-phase AC power generated by the explosion-proof permanent magnet generator is connected to the generator regulator via a cable. The generator regulator is used to rectify and regulate the AC power, and then output 24V DC power through the cable to supply the diesel engine control system and other electrical equipment, and to charge the battery power box. The power supply unit includes: The transformer is used to connect to the 1140V AC power system in the mine and is connected to the switching power supply and intrinsically safe power supply via cables; after conversion between the switching power supply and intrinsically safe power supply, voltage is supplied to the explosion-proof motor via cables. The PLC control unit is used to connect to the PLC expansion module via an internal bus; the digital input module collects switch signals, the analog input module collects analog signals, and the communication module performs data interaction; the output point of the PLC control unit is connected to the relay via a cable, and the relay controls the coil of the contactor, thereby controlling the on and off of the motor circuit.

3. The control system for the mining dual-power rubber-wheel scraper conveyor according to claim 2, characterized in that, The intrinsically safe display communicates with the ECU via the CAN bus to display vehicle status and fault information; the speed sensor is used for vehicle tachometer display; the fuel level sensor is installed on the fuel pump to detect the amount of fuel in the fuel tank; the hydraulic oil level and temperature sensor is installed on the hydraulic pump to detect the amount and temperature of hydraulic oil in the hydraulic tank. The methane sensor continuously monitors the methane concentration in the mine and provides emergency power-off protection when the concentration exceeds the limit. The diesel engine power supply unit includes: an explosion-proof permanent magnet generator, a generator regulator, and a battery power box; after the diesel engine starts, it drives the explosion-proof permanent magnet generator through the crankshaft belt. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator and converted into 24V DC power to supply the diesel engine control system and other electrical equipment of the whole machine, while charging the battery power box at the same time.

4. The control system for the mining dual-power rubber-wheel scraper conveyor according to claim 3, characterized in that, The power supply unit provides power to the explosion-proof motor and control system. After receiving the start / stop signal, the PLC control unit performs start / stop operations on the motor through the execution unit. The motor protection unit detects the motor operating parameters and provides overload, overcurrent and phase loss protection to the motor through the PLC control unit. The PLC control unit includes: a PLC controller and a PLC expansion module; the PLC expansion module includes a digital input / output module, an analog input module, and a communication module; the digital input module is used to acquire switch signals such as emergency stop, buttons, protectors, and methane power-off devices; the digital output module controls the PLC points to be turned on and off according to the program control logic, connects to intermediate relays to amplify power, and drives contactless devices, lighting, and voice alarm components; The analog input module refreshes the ADC conversion value every cycle. It is divided into current and voltage types and is used to acquire signals from voltage and current transmitters, motor winding temperature and pressure sensors.

5. The control system for a mining dual-power rubber-wheel scraper conveyor according to claim 4, characterized in that, This system enables safe switching between diesel engine and electric motor power. The switching sequence includes a travel-to-transportation operation sequence and a transportation-to-travel operation sequence. Electrical interlocking prevents misoperation. Walking to switch to transport operation: Turn the cab selector switch to the 0 position to ensure that there is no power input to the electronic control system; connect to the 1140V power supply system, at which point the electronic control system will be powered by 1140V; switch the travel mode to the transport mode, that is, perform the start and stop operation of the transport motor; Transportation switching walking operation: Disconnect the 1140V power supply system; rotate the cab selector switch to position 2; switch the transport mode to the travel mode and start the diesel engine for travel operation; if the diesel engine is running, it cannot be switched to transport mode, and the ECU power will be automatically cut off in transport mode; When the diesel engine is in operating or traveling mode, the dual power supply range is: An explosion-proof permanent magnet generator is driven by a diesel engine crankshaft belt. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator and then converted into 24V DC power to supply the diesel engine control system, PLC control unit and auxiliary system. When the motor is running or in transport mode, the dual-power supply range is: The mine's 1140V power system supplies power to two explosion-proof transport motors, the explosion-proof motor control system, and the auxiliary system. The 1140V three-phase AC power supplies the explosion-proof motors. The 1140V three-phase AC power is converted into AC220V, AC127V, AC36V / 24V, DC24V, and DC12V by a transformer and a switching power supply to power the explosion-proof motor control system and the auxiliary system.

6. The control system for a mining dual-power rubber-wheel scraper conveyor according to claim 5, characterized in that, The rail pressure sensor measures the real-time pressure of fuel in the common rail and converts it into a voltage signal, which is then sent to the ECU to control the injection quantity and timing. It also includes: Select the corresponding chromosome based on the fitness value for reproduction, perform crossover on the selected chromosome to produce new offspring, perform mutation on the newly generated offspring, replace the original population with the newly generated population, and repeat the iteration until the preset number of iterations is reached, at which point the iteration stops. Select the corresponding chromosome from the final population as the final control strategy; Based on the final control strategy, the amount and timing of fuel injection are controlled.

7. A control method for a mining dual-power rubber-wheel scraper conveyor, characterized in that, Applied to the system described in any one of claims 1 to 6, the method is applied to a mining dual-power rubber-wheel scraper conveyor comprising an explosion-proof diesel engine control system, an explosion-proof motor control system, an auxiliary system, and a dual-power switching system. The explosion-proof diesel engine control system uses an explosion-proof diesel engine as power to drive the rubber wheels; the explosion-proof motor control system uses two transport motors as power to drive the scraper conveyor; the auxiliary system is used to realize the status detection and protection of the entire machine; and the dual-power switching system is used to realize the safe switching between diesel engine and motor power. The method includes the following steps: Switching to walking mode, the diesel engine crankshaft belt drives an explosion-proof permanent magnet generator. The three-phase AC power generated by the generator is rectified and regulated by the generator regulator, then converted into 24V DC power to supply the diesel engine control system, PLC control unit, and auxiliary systems. The auxiliary systems include an emergency stop, methane power-off device, personnel access control system, video monitoring system, lighting system, audible and visual alarm system, remote control system, and hopper valve control system. The diesel engine control system controls the diesel engine to drive the rubber wheels for walking. The PLC control unit collects signals from the emergency stop, methane power-off device, and personnel access control system to control the entire machine to stop in an emergency. The PLC control unit collects signals from the operation buttons and remote control system to control the lighting system and hopper valve control system. The PLC control unit communicates with the ECU to obtain diesel engine operating parameters and provides warnings for forward and backward movement through the audible and visual alarm system. The video monitoring system communicates with the PLC control unit to obtain and display the overall machine operating parameters, and simultaneously collects and displays video footage from four cameras on the machine.

8. The control method for a mining dual-power rubber-wheel scraper conveyor according to claim 7, characterized in that, Switching to transport mode, the system supplies power to two explosion-proof transport motors, the explosion-proof motor control system, and auxiliary systems via the mine's 1140V power system. The 1140V three-phase AC power supplies the explosion-proof motors. This 1140V three-phase AC power is then converted via transformers and switching power supplies to AC220V, AC127V, AC36V / 24V, DC24V, and DC12V to power the explosion-proof motor control system and auxiliary systems. The PLC control unit collects signals from operation buttons and the remote control system to control the start / stop of the transport motors, the lighting system, and the audible and visual alarm system. The PLC control unit also collects signals from the emergency stop, methane power-off device, and personnel approach system to control the entire machine's emergency shutdown. The PLC control unit communicates with the video monitoring system to display the machine's operating parameters and simultaneously collects and displays video feeds from four cameras on the machine. During diesel engine operation: The real-time pressure of fuel in the common rail is measured by the rail pressure sensor and converted into a voltage signal and sent to the ECU; In the ECU, the optimization objective is defined, and the control parameters are encoded as genes of a genetic algorithm. These genes constitute chromosomes, which are the solutions. The control parameters include the injection quantity and injection timing. An initial population is randomly generated, which contains multiple chromosomes, each representing a control strategy. For each chromosome in the population, the operational performance is simulated using data from the rail pressure sensor and the engine model, and the fitness value of each chromosome is calculated based on the optimization objective. Chromosomes are selected based on fitness values ​​for reproduction. Crossover is performed on the selected chromosomes to produce new offspring, and mutation is performed on the newly generated offspring. Replace the original population with the newly generated population, and repeat the iteration until the preset number of iterations is reached; Select the corresponding chromosome from the final population as the final control strategy, and control the fuel injection quantity and timing according to the final control strategy.

Images