Multi-directional adaptive disassembly device, control system and calibration method for mine boring machine

Abstract

The present invention belongs to the technical field of intelligent manufacturing equipment, and discloses a multi-directional adaptive disassembly device, control system and calibration method for a mine boring machine. The disassembly device uses the coordinated operation of a base bracket, a rotating table, a sliding support, etc. to achieve flexible adjustment of the manipulator in multiple dimensions. The manipulator relies on a servo motor to cooperate with the oil cylinder to accurately control the grasping action, which greatly improves the grasping accuracy and stability. The circular track and sliding seat design further improves the overall operational flexibility and disassembly efficiency. The control system integrates electrical control, hydraulics, image processing analysis and data acquisition systems to achieve precise control and automated operation. In addition, the calibration method first obtains standard component data, and then adjusts the camera and control algorithm parameters to optimize the manipulator's grasping action. The present invention solves the problems of difficult disassembly and assembly of components, high safety risks, and low maintenance efficiency during the maintenance of mine boring machines, and comprehensively improves the efficiency and safety of mine boring machine maintenance.

Description

Technical Field

[0001] The present invention belongs to the technical field of intelligent manufacturing equipment, and specifically relates to a multi-directional adaptive disassembly device, a control system and a calibration method for a mine tunneling machine. Background Art

[0002] As a common piece of heavy equipment in modern mining operations, tunnel boring machines (TBMs) experience varying degrees of wear and deformation after prolonged, high-intensity operation, making the already complex disassembly and assembly process extremely difficult. Due to the large size and weight of many components of a tunnel boring machine, such as the main frame and scraper conveyor, large lifting equipment is required to assist in their assembly and disassembly. However, some large crane components, such as the bridge and counterweight, are bulky and heavy. In older factories or limited workspaces, the space available for large lifting equipment is limited, making accurate positioning and operation difficult.

[0003] The mine boring machines widely used in the domestic coal mining industry generally have a body height in the range of 1.5-3.26 meters, and a body span of about 3 meters. Taking the EBZ132 boring machine as an example, the widest part of the body of this model of boring machine can reach 2.24 meters, and the body height is 1.55 meters. If traditional large-scale lifting equipment is still used to lift and transport its large parts, a series of technical difficulties will be faced. In the existing technology, the boring machine maintenance device proposed in patent CN113247837A has improved the working conditions of the staff when repairing the boring machine to a certain extent. The device is designed with a height adjustment mechanism, a drive and a sliding mechanism, so that the working basket can be flexibly adjusted to its position, which is convenient for the staff to reach different positions of the boring machine for maintenance, avoiding the inefficiency caused by climbing escalators and improving maintenance efficiency. However, when faced with the complex disassembly and assembly of mine tunnel boring machines, this patented technology still has the problem of adjusting the maintenance position for personnel. It does not provide an effective solution for the disassembly of large components in narrow spaces, nor for the difficulties caused by wear and deformation of components. At the same time, the device cannot achieve precise disassembly operations when the gears and bearings are stuck inside the tunnel boring machine's gearbox. In addition, during the equipment disassembly and assembly process, if the high-pressure liquid that may remain inside the equipment is not scientifically handled before it is disassembled, it is very likely to cause a liquid injection accident. In terms of lifting operations, if the lifting point is improperly selected, the lifting equipment is not stable enough, or the operator's skills are not up to standard, the lifted components are prone to dangerous conditions such as shaking, tilting, or even falling during the lifting process. Once a component falls, it will not only damage the tunnel boring machine equipment, but also seriously threaten the lives of on-site maintenance personnel.

[0004] In summary, the disassembly and assembly of mine roadheaders during maintenance presents numerous challenges, ranging from structural design difficulties in disassembly, to the potential hazards of handling large components, to the increased difficulty of component wear and deformation, and numerous safety hazards. These issues severely restrict maintenance efficiency and quality. Therefore, it is urgent to develop new tools or technologies to assist with the maintenance and disassembly of mine roadheaders and address the challenges inherent in existing work methods. Summary of the Invention

[0005] In response to prominent issues such as difficulty in disassembling and assembling components, high safety risks, and low maintenance efficiency during the maintenance of mine tunneling machines, this invention is dedicated to developing a multi-directional adaptive disassembly device, control system, and calibration method for mine tunneling machines, to achieve efficient, safe, and precise component disassembly operations in all directions. The disassembly device designed in this invention has a unique adaptive adjustment mechanism that can be flexibly adjusted according to the size and shape of different components, greatly reducing manpower input and effectively reducing operational risks; the intelligent control system can monitor the entire disassembly process in real time, accurately control each link, and effectively avoid the occurrence of failures and accidents; and the precise calibration method further optimizes the performance of the device, ensuring that even in complex maintenance environments, the disassembly task can be completed stably and efficiently, significantly improving the efficiency and safety of mine tunneling machine maintenance as a whole.

[0006] To achieve the above-mentioned purpose, the present invention adopts the following technical solutions: a multi-directional adaptive disassembly device for a mining tunneling machine, comprising a base bracket and a rotating table arranged thereon, a stepper motor being installed on the base bracket, and the rotating table being started and stopped by the stepper motor, a sliding support and a linear motor being respectively installed on the rotating table, a mobile platform being slidably connected to the sliding support, the linear motor shaft being connected to the ball screw through a coupling, and the linear motor driving the ball screw to rotate drives the mobile platform to perform linear motion along the sliding support; an installation bracket is provided on the mobile platform, and a disassembly robot arm is provided on the installation bracket, and the disassembly robot arm completes the precise grasping operation of the parts to be repaired through electromechanical and hydraulic coordinated control.

[0007] As a further explanation and limitation of the above technical solution, the mounting bracket includes a back support bracket, a side support bracket and a bracket, the two side support brackets are installed on the mobile platform, the two brackets are located between the two side support brackets, and the four are located on the same side of the back support bracket; the disassembly robot arm includes two articulated supports, a rotating shaft and a connecting rod, the connecting rod is connected to the articulated support through a rotating shaft, a servo motor is installed on the back support, the servo motor shaft is connected to one of the rotating shafts through a coupling, a swing arm is rotatably arranged between the two brackets through a connecting shaft, one end of the swing arm is hinged to the two connecting rods through a telescopic arm, and the other end is hinged to a robot, and a first oil cylinder is hinged between the robot and the bracket, and the two first oil cylinders are used together to accurately control the grasping action of the robot.

[0008] As a further explanation and limitation of the above technical solution, the manipulator includes a connecting end, and a cylinder connecting ear and a manipulator connecting seat respectively installed thereon, two clamping jaws are respectively installed on the manipulator connecting seat through a rotating shaft, and meshing gears are respectively installed on the two rotating shafts, and a protective baffle is installed on the manipulator connecting seat, and the protective baffle is used to protect the gears and rotating shaft from external impacts. A cylinder articulated seat is provided on one of the clamping jaws, and the cylinder articulated seat and the cylinder connecting ear are connected by a second cylinder, and the second cylinder is used to control the opening and closing of the clamping jaws to achieve stable grasping and precise positioning of the parts to be repaired.

[0009] As a further explanation and limitation of the above technical solution, the clamp includes a fixed seat, a connecting plate is installed on the fixed seat through an adjusting screw, and a grabbing splint is provided on the connecting plate. The grabbing splint adjusts the position of the connecting plate through the adjusting screw to ensure that the clamp adapts to components of different sizes and improves the grabbing accuracy and stability.

[0010] As a further supplement to the above technical solution, a slip ring is installed on the fixed seat through a guide rod. The slip ring cooperates with the adjusting screw to realize axial movement of the connecting plate, thereby improving the flexibility of the grabbing range of the grabbing splint and ensuring the adaptability of the device under different working conditions.

[0011] As a further explanation and limitation of the above technical solution, a slide rail is provided on the sliding support, and a corresponding slider is provided at the bottom of the mobile platform. The cooperation between the slide rail and the slider ensures the free sliding of the mobile platform in the horizontal direction.

[0012] As a further explanation and limitation of the above technical solution, the base bracket is connected to the rotating table through a shaft sleeve and a slewing bearing. An external gear is installed on the outer ring of the slewing bearing. The external gear is engaged with the output gear of the stepper motor. The stepper motor adjusts the angle of the rotating table through gear engagement transmission to ensure the flexibility and accuracy of the disassembly device in multi-directional operations.

[0013] As a further supplement to the above technical solution, a circular track is provided on the base bracket, and a sliding seat is installed on the rotating table. The sliding seat moves along the circular track and coordinates with the stepping motor to achieve multi-angle rotation of the rotating table, thereby improving the operational flexibility and disassembly efficiency of the device.

[0014] A control system for the multi-directional adaptive disassembly device of the above-mentioned mine roadheader includes an electrical control system, a hydraulic system, an image processing and analysis system, and a data acquisition system; the electrical control system includes a programmable logic controller, a frequency converter, relays, an electrical control cabinet, and connecting lines; the programmable logic controller is used to receive sensor signals from the data acquisition system and output data from the image processing and analysis system, coordinate the motion parameters of the servo motor, stepper motor, and linear motor through a preset control program and PID algorithm, and generate action instructions for the first and second cylinders; the frequency converter is used to adjust the drive frequency of the stepper motor and linear motor, Realize start-stop and speed control; the relay is used to switch high-power circuits to ensure the safety interlock between the hydraulic system and the motor drive; the hydraulic system includes a hydraulic pump station, an electromagnetic reversing valve, a hydraulic pipeline, a first oil cylinder and a second oil cylinder. The hydraulic pump station provides high-pressure oil power for the oil cylinder; the electromagnetic reversing valve switches the direction of the oil circuit according to the instructions issued by the programmable logic controller, controls the first oil cylinder to drive the grasping action of the manipulator, and controls the second oil cylinder to adjust the opening and closing of the clamping jaws; the image processing and analysis system includes a binocular camera, an industrial computer and an image processing algorithm module. The binocular camera is installed on the mounting bracket and uses stereo vision technology to collect multi-angle images of the parts to be repaired. The industrial computer runs the image recognition algorithm to extract the three-dimensional coordinates, posture angle and surface features of the target component, and feeds the processed data back to the programmable logic controller for planning the movement path and grasping strategy of the robot arm; the data acquisition system includes a position sensor, an infrared laser sensor, a magnetostrictive displacement sensor, an encoder, a force sensor and a data acquisition card; two start and stop sensing plates are installed at the bottom of the rotating table. The position sensor monitors the position of the rotating table in real time through the two sensing plates at the bottom of the rotating table, and controls the start and stop of the stepper motor through the driver of the stepper motor; two infrared laser sensors are installed on both sides of the sliding support respectively, and are used to The system is used to detect the moving distance of the mobile platform and ensure the precise positioning of the mobile platform by controlling the running speed and direction of the linear motor; the magnetostrictive displacement sensor is installed on the first oil cylinder and the second oil cylinder to monitor the piston rod displacement of the two oil cylinders in real time, thereby adjusting the grasping action and strength of the manipulator; the encoder is installed on the servo motor shaft to measure the rotation angle and speed of the servo motor; the force sensor is installed at the grasping part of the manipulator to detect the force applied when the manipulator grasps the part to be repaired; the data acquisition card converts the signals of each sensor into digital signals and transmits them to the programmable logic controller for comprehensive analysis and control decision-making.

[0015] A calibration method mainly includes the following steps:

[0016] S1 Obtaining Standard Component Data: Based on the specific model of the mining roadheader, obtain the accurate size and shape data of each standard component of the corresponding model of the roadheader from the manufacturer to ensure the accuracy and adaptability of the standard component data used;

[0017] S2: Place the standard component: Place the standard component associated with the acquired data within the working range of the disassembly device to provide calibration objects and working conditions for subsequent calibration operations;

[0018] S3 binocular camera image acquisition and processing: The binocular camera acquires image data of standard components, transmits the acquired image data to the industrial computer, processes the image of the standard components using the image processing algorithm module, and calculates the actual position and posture data of the standard components in the image;

[0019] S4 binocular camera parameter adjustment: Compare the calculated actual position and attitude data with the real position and attitude data of the standard component to obtain position deviation and attitude deviation data; based on the position deviation and attitude deviation data, adjust the binocular camera's focal length, aperture, and image acquisition angle parameters to reduce the deviation;

[0020] S5 grabbing action data acquisition: Start the servo motor, the first cylinder, and the second cylinder to make the robot grasp the standard component, and use the magnetostrictive displacement sensor, encoder, and force sensor to collect data in real time;

[0021] S6 Control Algorithm Parameter Adjustment: Compare the collected sensor data with the theoretical data of the grasping action of the standard component, and adjust the proportional coefficient, integral coefficient, and differential coefficient in the PID control algorithm based on the comparison results;

[0022] S7 repeats calibration until the standard is met: repeat steps 3 to 6 times until the deviation between the position data calculated after processing the image data collected by the binocular camera and the actual data is controlled within ±3 mm, the deviation between the posture data and the actual data is controlled within ±1°, and at the same time, the deviation between the data collected by the magnetostrictive displacement sensor and the theoretical displacement data of the grasping action is controlled within ±1 mm, the deviation between the data collected by the force sensor and the theoretical grasping force data of the grasping action is controlled within ±8% of the grasping force, the deviation between the angle in the encoder data and the theoretical rotation angle data is controlled within ±0.3°, and the deviation between the speed and the rated speed data is controlled within ±3% of the rated speed. The calibration of the multi-directional adaptive disassembly device of the mine roadheader is completed.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] 1. The present disassembly device utilizes a coordinated design of a base support, rotating platform, sliding support, mobile platform, and disassembly robot arm, enabling multi-dimensional adjustment and flexible adaptation to varying component sizes and shapes. For example, when working in confined spaces, the rotating platform, utilizing a circular track and sliding support, enables multi-angle, narrow-range rotation, avoiding collisions with obstacles and facilitating access for the disassembly robot arm to the component being repaired, enhancing operational convenience in complex locations.

[0025] 2. The manipulator of this invention precisely controls the gripping motion through a first hydraulic cylinder, while a second hydraulic cylinder precisely controls the opening and closing of the gripping jaws. The gripping jaws can adjust the position of the connecting plate using an adjustment screw and, in conjunction with a slip ring, achieve axial movement. This allows for close fit with components of varying sizes and shapes, effectively improving gripping accuracy and stability. This reduces the risk of component shaking and tilting during the gripping process, preventing damage and ensuring component safety during disassembly and handling.

[0026] 3. The control system of the present invention integrates an electrical control system, a hydraulic system, an image processing and analysis system, and a data acquisition system. Various sensors in the data acquisition system monitor key data during the disassembly process in real time, such as force sensors monitoring gripping force and magnetostrictive displacement sensors monitoring cylinder piston rod displacement. These sensors transmit this data to a programmable logic controller (PLC). Based on this data, the controller promptly adjusts the movements of the motors and cylinders, achieving precise control, effectively preventing malfunctions and accidents, and ensuring operator safety.

[0027] 4. This invention utilizes an image processing and analysis system to capture images of the components to be repaired. After processing by an industrial computer, this data is provided to the electrical control system, enabling automated control of stepper motors, linear motors, servo motors, and hydraulic cylinders. Compared to traditional manual disassembly methods, this significantly reduces labor and time, improving maintenance efficiency and reducing costs for mine roadheaders.

[0028] 5. The calibration method of this invention accurately calibrates the device by acquiring standard component data and adjusting binocular camera parameters and control algorithm parameters. Calibration is repeated until all data deviations are within the allowable error range. This effectively optimizes the robot's grasping motion, ensuring that the robot can stably and accurately perform disassembly tasks even in complex environments, improving the overall operating efficiency and safety of the device.

[0029] 6. The disassembly device of the present invention does not require reliance on large lifting equipment, thus avoiding the problem of large lifting equipment being difficult to use in old factories or sites with limited space. It expands the scope of application under different site conditions, making the maintenance work of mine tunneling machines no longer restricted by site conditions, and providing more mining companies with efficient and feasible maintenance solutions.

[0030] 7. This invention takes safety into full consideration in its design, resolving issues such as unscientific lifting point selection and insufficient lifting equipment stability in traditional disassembly methods. It also reduces the risk of components shaking, tilting, or even falling during the lifting process. Furthermore, it rationally addresses potential safety hazards such as residual high-pressure liquids within the equipment, creating a safer working environment for maintenance personnel. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 This is a schematic diagram of the overall structure of the multi-directional adaptive disassembly device for a mine boring machine in the present invention;

[0032] Figure 2 This is an assembly diagram of the disassembly robot arm in the present invention;

[0033] Figure 3 It is a structural diagram of the manipulator in the present invention;

[0034] Figure 4 This is an assembly diagram of the sliding support and the mobile platform in the present invention;

[0035] Figure 5 Schematic diagram of the cooperation between the base bracket and the rotating platform in the present invention;

[0036] Figure 6 It is a structural block diagram of the control system in the present invention;

[0037] Figure 7 is a flow chart of the calibration method of the present invention;

[0038] Figure 8 This is a performance comparison chart between the present invention and the traditional calibration method.

[0039] In the figure: the base bracket is 1, the rotary table is 2, the stepper motor is 3, the sliding support is 4, the mobile platform is 5, the linear motor is 6, the mounting bracket is 7, the disassembly robot arm is 8, the ball screw is 9, the servo motor is 10, the slide rail is 11, the slider is 12, the bushing is 13, the slewing bearing is 14, the external gear is 15, the output gear is 16, the annular track is 17, the sliding seat is 18, the position sensor is 19, the infrared laser sensor is 20, the binocular camera is 21, the magnetostrictive displacement sensor is 22, the encoder is 23, the force sensor is 24, the electrical control system is 100, the hydraulic system is 200, the image processing and analysis system is 300, and the data acquisition system is 400.

[0040] The specific structure of the mounting bracket is: the back support is 701, the side support is 702, and the bracket is 703;

[0041] Disassemble the specific structure of the robotic arm: the articulated support is 801, the rotating shaft is 802, the connecting rod is 803, the connecting shaft is 804, the swing arm is 805, the telescopic arm is 806, the manipulator is 807, the first cylinder is 808, the connecting end is 8071, the cylinder connecting ear is 8072, the manipulator connecting seat is 8073, the rotating shaft is 8074, the gear is 8075, the clamp is 8076, the cylinder articulated seat is 8077, the second cylinder is 8078, the protective baffle is 8079, the fixed seat is 80761, the connecting plate is 80762, the grabbing splint is 80763, the guide rod is 80764, and the slip ring is 80765. DETAILED DESCRIPTION

[0042] In order to further illustrate the technical solution of the present invention, Figures 1 to 8 , the present invention is further illustrated by two embodiments in combination with actual applications. Example 1

[0043] As attached Figures 1 to 6As shown, a multi-directional adaptive disassembly device for a mining tunneling machine comprises a base support 1 and a rotary platform 2. The base support 1 is installed on the floor of a maintenance workshop. The rotary platform 2 is connected to the base support 1 using a sleeve 13 and a slewing bearing 14. During installation, the outer gear 15 on the outer ring of the slewing bearing 14 must be properly engaged with the output gear 16 of the stepper motor 3, and the meshing clearance must meet the equipment design requirements. The stepper motor 3 is mounted on the base support 1. Next, the sliding support 4 and linear motor 6 are installed on the rotary platform 2 according to the designed positions. A slide rail 11 is installed on the surface of the sliding support 4, and a slider 12 is installed on the bottom of the mobile platform 5. After installation, commissioning is performed to ensure smooth engagement between the slider 12 and the slide rail 11, allowing the mobile platform 5 to slide freely and smoothly in the horizontal direction without any jamming. Next, the shaft of the linear motor 6 is securely connected to the ball screw 9 via a coupling to ensure coaxiality and prevent eccentricity during operation that could damage the equipment. Debug the linear motor 6 so that it can drive the ball screw 9 to rotate and drive the mobile platform 5 to perform precise linear motion along the sliding support 4. Finally, install the mounting bracket 7 on the mobile platform 5. The mounting bracket 7 consists of a back support 701, a side support frame 702 and a bracket 703. During installation, the two side support frames 702 should be symmetrically and firmly installed on the mobile platform 5. The two brackets 703 are located between the two side support frames 702, and all four are located on the same side of the back support 701. The connection between the various components must be tight and reliable to ensure the stability of the overall structure of the mounting bracket 7. Install and disassemble the robot arm 8 on the mounting bracket 7, in which the two articulated supports 801 are fixed to the back support 701, and the connecting rod 803 is connected to the articulated support 801 through the rotating shaft 802 to ensure the rotation flexibility of the rotating shaft 802. Install the servo motor 10 on the back support 701, and connect the shaft of the servo motor 10 to one of the rotating shafts 802 through a coupling to ensure the firmness of the connection and transmission efficiency. Between the two brackets 703, a swing arm 805 is rotatably arranged via a connecting shaft 804. One end of the swing arm 805 is hinged to the two connecting rods 803 via a telescopic arm 806, and the other end is hinged to a manipulator 807. A first oil cylinder 808 is hinged between the manipulator 807 and the bracket 703. The two first oil cylinders 808 must be installed symmetrically, and the telescopic movement of their piston rods must be ensured to accurately control the grasping action of the manipulator 807. The disassembled manipulator 8 is debugged to check the range of motion and flexibility of each joint to ensure that it can achieve flexible movement at multiple angles. The manipulator 807 includes a connecting end 8071, an oil cylinder connecting ear 8072, and a manipulator connecting base 8073. On the manipulator connecting base 8073, two clamps 8076 are mounted via a rotating shaft 8074, and meshing gears 8075 are mounted on the two rotating shafts 8074 to ensure the meshing accuracy of the gears 8075 so that the two clamps 8076 can open and close synchronously.A protective baffle 8079 is installed on the manipulator connection base 8073 to protect the gear 8075 and rotating shaft 8074 from external impact. A cylinder articulated base 8077 is installed on one of the clamping jaws 8076. A second cylinder 8078 connects the cylinder articulated base 8077 to the cylinder connection ear 8072. The second cylinder 8078 is adjusted to ensure that it can accurately control the opening and closing of the clamping jaw 8076, achieving stable grasping and precise positioning of the part to be repaired. The clamping jaw 8076 includes a fixed base 80761, to which a connecting plate 80762 is mounted via an adjustment screw. A gripping clamp 80763 is provided on the connecting plate 80762.

[0044] It should be noted that, depending on the size of the component being repaired, the position of connecting plate 80762 can be adjusted using an adjusting screw, ensuring that clamping jaws 8076 can adapt to components of varying sizes, improving gripping accuracy and stability. Furthermore, a slip ring 80765 is mounted on fixed base 80761 via guide rod 80764. This slip ring, in conjunction with the adjusting screw, enables axial movement of connecting plate 80762, further enhancing the flexibility of the gripping range of gripping clamp 80763 and ensuring the device's adaptability under varying working conditions. Example 2

[0045] In order to improve the operation flexibility and disassembly efficiency of the device. Figure 6 As shown, we have added the following improvements based on the above embodiment: a circular track 17 is provided on the base bracket 1, and a sliding seat 18 is installed on the rotating table 2, so that the sliding seat 18 can move smoothly along the circular track 17. The cooperation between the sliding seat 18 and the circular track 17 and the coordinated movement of the stepping motor 3 realize the multi-angle rotation of the rotating table 2.

[0046] As attached Figure 6As shown, a control system includes an electrical control system 100, a hydraulic system 200, an image processing and analysis system 300, and a data acquisition system 400. The following details the specific structural connections and configurations of each system: The electrical control system 100 includes a programmable logic controller, a frequency converter, relays, an electrical control cabinet, and connecting lines. The programmable logic controller, frequency converter, relays, and other components are installed in the electrical control cabinet. The connecting lines are laid according to the electrical schematic diagram to ensure that the lines are connected correctly and firmly, without any loose connections or short circuits. After the connection is completed, the electrical control cabinet is grounded to ensure safe operation of the equipment. A position sensor 19 is installed at the bottom of the turntable 2 so that it can monitor the position information of the turntable 2 in real time through two sensor plates at the bottom of the turntable 2. Two infrared laser sensors 20 are installed on both sides of the sliding support 4 to ensure that they can accurately detect the movement distance of the mobile platform 5. Magnetostrictive displacement sensors 22 are installed on the first cylinder 808 and the second cylinder 8078 to monitor the piston rod displacement of the two cylinders in real time. An encoder 23 is installed on the shaft of the servo motor 10 to measure the rotation angle and speed of the servo motor 10. A force sensor 24 is installed at the grasping part of the manipulator 807 to detect the force applied when the manipulator 807 grasps the part to be repaired. The above-mentioned sensor is connected to the programmable logic controller through a data acquisition card to ensure that the signals collected by the sensor can be accurately and timely transmitted to the programmable logic controller for comprehensive analysis and control decision-making. The hydraulic system 200 includes a hydraulic pump station, an electromagnetic reversing valve, a hydraulic pipeline, a first oil cylinder 808 and a second oil cylinder 8078. Connect the hydraulic pump station, the electromagnetic reversing valve and the hydraulic pipeline to ensure the sealing of the hydraulic system and prevent leakage. Add hydraulic oil that meets the equipment requirements to the hydraulic pump station, and debug the hydraulic pump station so that it can provide stable high-pressure oil power to the cylinder. According to the instructions of the programmable logic controller in the electrical control system 100, the electromagnetic reversing valve is debugged to ensure that it can accurately switch the direction of the oil circuit, control the first cylinder 808 to drive the grasping action of the manipulator 807, and control the second cylinder 8078 to adjust the opening and closing of the clamping jaws 8076. The image processing and analysis system 300 includes a binocular camera 21, an industrial computer, and an image processing algorithm module. The binocular camera 21 is mounted on the mounting bracket 7 to ensure that its field of view covers the working area of ​​the component to be repaired. The binocular camera 21 is connected to the industrial computer, and the image processing algorithm module is installed and debugged. The binocular camera 21 is operated to capture multi-angle images of the component to be repaired using stereo vision technology. The industrial computer runs an image recognition algorithm to extract the three-dimensional coordinates, attitude angle, and surface features of the target component. The processed data is fed back to the programmable logic controller for planning the motion path and grasping strategy of the manipulator 807.

[0047] In the actual application of the multi-directional adaptive disassembly device of a mine boring machine, due to the complex and changeable working environment, there are differences in the size, shape and position of the parts to be repaired, and there are inevitable errors in the mechanical structure and sensors during the manufacturing and installation process. These factors will affect the accuracy and stability of the manipulator's grasping action. If the manipulator cannot accurately grasp the parts, it will not only reduce the disassembly efficiency, but may also cause damage to the parts during the grasping and transportation process, and even cause safety accidents. Traditional calibration methods are difficult to adapt to the special needs of mine boring machine disassembly operations and cannot effectively solve the above problems. Therefore, based on the multi-directional adaptive disassembly device of a mine boring machine and the corresponding control system described in the above two embodiments, it is crucial to develop a precise calibration method for the disassembly device to improve the overall performance and operational safety of the device.

[0048] As attached Figure 7 As shown, the specific calibration method steps are as follows:

[0049] S1 Obtain standard component data: According to the specific model of the mining roadheader, obtain the accurate size and shape data of each standard component of the corresponding model of the roadheader from the manufacturer. This data is the basis of the calibration work and its accuracy and adaptability must be guaranteed.

[0050] S2 Placement of standard components: Place the standard components associated with the acquired data within the working range of the disassembly device. When placing, ensure that the position and posture of the standard components meet the calibration requirements, providing accurate calibration objects and good working conditions for subsequent calibration operations.

[0051] S3 Binocular Camera Image Acquisition and Processing: Activate the binocular camera 21 to acquire image data of the standard component and transmit the acquired image data to the industrial computer. Use the image processing algorithm module to process the image of the standard component and calculate the actual position and posture data of the standard component in the image.

[0052] S4 Binocular Camera Parameter Adjustment: Compare the calculated actual position and attitude data with the actual position and attitude data of the standard component to obtain position and attitude deviation data. Based on this position and attitude deviation data, adjust the binocular camera 21's focal length, aperture, image acquisition angle, and other parameters. Through repeated adjustments and testing, gradually reduce the deviation.

[0053] S5: Grasping Action Data Collection: Servo motor 10, first cylinder 808, and second cylinder 8078 are activated, causing manipulator 807 to grasp the standard component. During the grasping process, magnetostrictive displacement sensor 22, encoder 23, and force sensor 24 are used to collect real-time data, including cylinder piston rod displacement, servo motor rotation angle and speed, and grasping force.

[0054] S6 control algorithm parameter adjustment: Compare the collected sensor data with the theoretical data of the grasping action of the standard component, and adjust the proportional coefficient, integral coefficient and differential coefficient in the PID control algorithm based on the comparison results to optimize the performance of the control algorithm.

[0055] S7 repeats the calibration until the standard is met: repeat steps 3 to 6 times until the deviation between the position data calculated after processing the image data collected by the binocular camera 21 and the actual data is controlled within ±3 mm, and the deviation between the posture data and the actual data is controlled within ±1°. At the same time, the deviation between the data collected by the magnetostrictive displacement sensor 22 and the theoretical displacement data of the grasping action is controlled within ±1 mm, the deviation between the data collected by the force sensor 24 and the theoretical grasping force data of the grasping action is controlled within ±8% of the grasping force, the deviation between the angle in the data collected by the encoder 23 and the theoretical rotation angle data is controlled within ±0.3°, and the deviation between the speed and the rated speed data is controlled within ±3% of the rated speed. The calibration of the multi-directional adaptive disassembly device of the mine roadheader is completed.

[0056] In order to verify the advantages of the calibration method of the present invention in terms of grasping accuracy, operating efficiency, safety and adaptability. We conducted experiments by comparing the calibration method of the present invention with the traditional calibration method, in which the traditional calibration method adopts manual calibration, while the present invention combines a binocular camera, a variety of sensors and a data acquisition system composed of an industrial computer running LabVIEW or MATLAB software. The calibration targets use standard components of mining tunneling machines (such as EBZ132, EBZ160 and other different models of gearboxes, scraper conveyor components). In a calibration area of ​​3m×3m×2m, the experimental setting uses the disassembly device using the calibration method of the present invention as the experimental group, and the traditional method as the control group. Through a series of experimental processes, such as grasping accuracy verification (recording position and attitude angle deviation), operating efficiency comparison (recording calibration and disassembly time), safety testing (monitoring grasping force fluctuations and component shaking amplitude), adaptability verification (grasping test of components of different sizes) and long-term stability testing (continuous operation recording accuracy and response time), and analysis is carried out according to the corresponding evaluation indicators. As shown in the attached figure Figure 8As shown in the figure, the experimental results show that the present invention is significantly superior to the traditional method in multiple key performance indicators, which are as follows: the grasping accuracy can be controlled at ≤0.5mm, which is 4 times higher than the accuracy of the traditional method ≥2.0mm, and is suitable for scenes with extremely high precision requirements such as grasping and assembling precision electronic components; the calibration time is ≤10 minutes, which is much shorter than the ≥30 minutes of the traditional method, and the efficiency is improved by 200%, which has outstanding advantages in frequent calibration workflows; the grasping force stability σ≤5N, which is 3 times higher than the traditional method ≥15N, and can ensure the reliability and safety of grasping fragile and deformable objects; the component shaking rate is ≤5%, which is much lower than the traditional method The method ≥30% achieves a 6-fold increase in safety, reducing the risk of equipment failure and safety hazards to operators; the grasping success rate ≥98%, which is higher than the traditional method ≤70%, and the adaptability is improved by 40%, which can adapt to complex and changeable work scenarios, and improve work efficiency and production continuity; the precision decay rate ≤1%, compared with the traditional method ≥5%, the long-term stability is improved by 5 times, reducing equipment calibration or replacement and extending the service life; the response time stability ≤2ms, compared with the traditional method ≥10ms, the real-time performance is improved by 5 times, which meets the work requirements with high real-time requirements such as high-speed grasping and handling of automated production lines, and provides a strong guarantee for efficient and precise automated operations.

[0057] Its operation working principle:

[0058] During the actual disassembly of a mine roadheader component, the binocular camera 21 in the image processing and analysis system 300 is first activated to capture multi-angle images of the component to be repaired. An industrial computer runs an image recognition algorithm to extract the target component's three-dimensional coordinates, attitude angle, and surface features, and transmits the processed data to the programmable logic controller in the electrical control system 100. Based on a preset control program and PID algorithm, the programmable logic controller coordinates and controls the motion parameters of the stepper motor 3, linear motor 6, and servo motor 10, combining signals from the position sensor 19 and infrared laser sensor 20 in the data acquisition system 400. The stepper motor 3 drives the rotary table 2 to rotate, adjusting its angle to align the disassembly robot 8 with the component to be repaired. The linear motor 6 drives the ball screw 9 to rotate, driving the mobile platform 5 in linear motion along the sliding support 4, bringing the disassembly robot 8 closer to the component to be repaired. The servo motor 10 drives the connecting rod 803 via the rotating shaft 802, thereby controlling the swing arm 805 to oscillate, bringing the robot 807 closer to the target component. When manipulator 807 approaches the component to be repaired, the electrical control system 100 issues a command to activate the hydraulic system 200. The hydraulic pump station provides high-pressure oil power to the first and second cylinders 808 and 8078. The electromagnetic reversing valve switches the oil flow direction according to the command from the programmable logic controller. The first cylinder 808 drives manipulator 807 to grasp the component, while the second cylinder 8078 controls the opening and closing of the gripper 8076, achieving stable grasping of the component to be repaired. During the grasping process, the force sensor 24 measures the force applied by manipulator 807 to grasp the component in real time, and the magnetostrictive displacement sensor 22 monitors the displacement of the cylinder piston rod. The data acquisition system 400 transmits this data in real time to the programmable logic controller. Based on this data, the programmable logic controller promptly adjusts the operation of the motors and cylinders to ensure a smooth and safe grasping process and avoid damage to the component to be repaired. After grasping the component, the coordinated movement of the stepper motor 3, linear motor 6, and servo motor 10 is controlled to transfer the component to a designated maintenance area for further repair work. During the transfer process, the data collected by the data acquisition system 400 ensures that the parts handling process is safe and reliable.

[0059] When encountering parts to be repaired of different sizes, the position of the connecting plate 80762 is adjusted by adjusting the adjustment screws on the clamping jaws 8076 according to the size of the part, so that the grasping splint 80763 can closely fit the surface of the part, adapt to changes in part size, and improve grasping accuracy and stability. At the same time, the slip ring 80765 cooperates with the adjustment screws to achieve axial movement of the connecting plate 80762, further expanding the grasping range of the grasping splint 80763 and ensuring that the device can work effectively under different working conditions. For parts to be repaired with uneven surfaces or irregular shapes, the image processing and analysis system 300 collects image data from more angles and uses image processing algorithms to more accurately identify component features, thereby planning a more appropriate motion path and grasping strategy for the manipulator 807. Based on these plans, the electrical control system 100 more precisely controls the movements of each motor and cylinder, allowing the manipulator 807 to better fit the surface of the part and achieve stable grasping. In maintenance areas with limited space, the circular track 17 on the base bracket 1 and the sliding seat 18 on the turntable 2, along with the stepper motor 3, enable multi-angle, small-range rotation of the turntable 2. During rotation, feedback from the position sensor 19 is combined to precisely control the rotation angle of the turntable 2, preventing collisions between the disassembly robot arm 8 and surrounding obstacles, thereby improving operational flexibility and safety.

[0060] The above shows and describes the main features and advantages of the present invention. It is obvious to those skilled in the art that the specific implementation of the present invention is not limited to the details of the above exemplary embodiments. Moreover, without departing from the spirit or essential characteristics of the present invention, the creative ideas and design concepts of the present invention can be implemented in other specific forms, which should be equivalent to the scope of protection disclosed in the technical solution of the present invention. Therefore, from all perspectives, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, it is intended that all changes that fall within the meaning and scope of the equivalent elements of the claims are included in the present invention.

[0061] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A multi-directional adaptive disassembly device for a mine boring machine, comprising a base support (1) and a rotating platform (2) arranged thereon, characterized in that: A stepper motor (3) is installed on the base support (1), and the rotating platform (2) is driven by the stepper motor (3) to start and stop. A sliding support (4) and a linear motor (6) are respectively installed on the rotating platform (2). A mobile platform (5) is slidably connected to the sliding support (4). The axis of the linear motor (6) is connected to the ball screw (9) through a coupling. The linear motor (6) drives the ball screw (9) to rotate and drives the mobile platform (5) to move linearly along the sliding support (4). A mounting bracket (7) is provided on the mobile platform (5), and a disassembly robot arm (8) is provided on the mounting bracket (7). The disassembly robot arm (8) completes the precise grasping operation of the parts to be repaired through electromechanical and hydraulic coordinated control. An annular track (17) is provided on the base support (1), and a sliding seat (18) is installed on the rotating platform (2). The sliding seat (18) moves along the annular track (17) and realizes multi-angle rotation of the rotating platform (2) by coordinating with the stepping motor (3), thereby improving the operating flexibility and disassembly efficiency of the device; The mounting bracket (7) includes a back support bracket (701), a side support bracket (702) and a bracket (703), wherein the two side support brackets (702) are mounted on the mobile platform (5), the two brackets (703) are located between the two side support brackets (702), and the four brackets (703) are located on the same side of the back support bracket (701); the disassembly robot arm (8) includes two articulated supports (801), a rotating shaft (802) and a connecting rod (803), wherein the connecting rod (803) is connected to the articulated support (801) via the rotating shaft (802), and a connecting rod (803) is mounted on the back support bracket (701). A servo motor (10), wherein the shaft of the servo motor (10) is connected to one of the rotating shafts (802) via a coupling, and a swing arm (805) is rotatably provided between the two brackets (703) via a connecting shaft (804), one end of the swing arm (805) is hinged to the two connecting rods (803) via a telescopic arm (806), and the other end is hinged to a manipulator (807), and a first oil cylinder (808) is hinged between the manipulator (807) and the bracket (703), and the two first oil cylinders (808) are used together to accurately control the grasping action of the manipulator (807); The manipulator (807) includes a connecting end (8071), and a cylinder connecting ear (8072) and a manipulator connecting base (8073) respectively mounted thereon. Two clamping claws (8076) are respectively mounted on the manipulator connecting base (8073) via a rotating shaft (8074). Meshing gears (8075) are respectively mounted on the two rotating shafts (8074). A protective baffle (807) is mounted on the manipulator connecting base (8073). 9), the protective baffle (8079) is used to protect the gear (8075) and the rotating shaft (8074) from external impact. A cylinder hinge seat (8077) is provided on one of the clamping jaws (8076), and the cylinder hinge seat (8077) and the cylinder connecting ear (8072) are connected via a second cylinder (8078). The second cylinder (8078) is used to control the opening and closing of the clamping jaws (8076) to achieve stable grasping and precise positioning of the parts to be repaired.

2. The multi-directional adaptive disassembly device for a mine boring machine according to claim 1, characterized in that: The clamping jaw (8076) includes a fixing seat (80761), a connecting plate (80762) is mounted on the fixing seat (80761) by means of an adjusting screw, a grabbing splint (80763) is provided on the connecting plate (80762), and the grabbing splint (80763) is used to adjust the position of the connecting plate (80762) by means of an adjusting screw, thereby ensuring that the clamping jaw (8076) can adapt to components of different sizes and improve grabbing accuracy and stability.

3. The multi-directional adaptive disassembly device for a mine boring machine according to claim 2, characterized in that: A slip ring (80765) is installed on the fixed seat (80761) through a guide rod (80764). The slip ring (80765) cooperates with the adjusting screw to realize the axial movement of the connecting plate (80762), thereby improving the flexibility of the grabbing range of the grabbing splint (80763) and ensuring the adaptability of the device under different working conditions.

4. A multi-directional adaptive disassembly device for a mine boring machine according to any one of claims 1 to 3, characterized in that: A slide rail (11) is provided on the sliding support (4), and a corresponding slider (12) is provided at the bottom of the mobile platform (5). The cooperation between the slide rail (11) and the slider (12) ensures that the mobile platform (5) can slide freely in the horizontal direction.

5. The multi-directional adaptive disassembly device for a mine boring machine according to claim 4, characterized in that: The base bracket (1) is connected to the rotating table (2) through a shaft sleeve (13) and a slewing bearing (14). An external gear (15) is installed on the outer ring of the slewing bearing (14). The external gear (15) is engaged with an output gear (16) of a stepper motor (3). The stepper motor (3) adjusts the angle of the rotating table (2) through gear meshing transmission, thereby ensuring the flexibility and accuracy of the disassembly device in multi-directional operations.

6. A control system for the multi-directional adaptive disassembly device of a mine boring machine according to any one of claims 1 to 5, characterized in that: It includes an electrical control system (100), a hydraulic system (200), an image processing and analysis system (300), and a data acquisition system (400); The electrical control system (100) includes a programmable logic controller, a frequency converter, a relay, an electrical control cabinet and connecting lines. The programmable logic controller is used to receive sensor signals from the data acquisition system (400) and output data from the image processing and analysis system (300), coordinate the motion parameters of the servo motor (10), the stepper motor (3) and the linear motor (6) through a preset control program and a PID algorithm, and generate action instructions for the first oil cylinder (808) and the second oil cylinder (8078); the frequency converter is used to adjust the driving frequency of the stepper motor (3) and the linear motor (6) to achieve start-stop and speed control; the relay is used to switch high-power circuits to ensure the safety interlocking of the hydraulic system (200) and the motor drive; The hydraulic system (200) includes a hydraulic pump station, an electromagnetic reversing valve, a hydraulic pipeline, a first oil cylinder (808) and a second oil cylinder (8078). The hydraulic pump station provides high-pressure oil power to the oil cylinder; the electromagnetic reversing valve switches the direction of the oil circuit according to the instruction issued by the programmable logic controller, controls the first oil cylinder (808) to drive the grasping action of the manipulator (807), and controls the second oil cylinder (8078) to adjust the opening and closing of the clamping claw (8076); The image processing and analysis system (300) includes a binocular camera (21), an industrial computer, and an image processing algorithm module. The binocular camera (21) is mounted on a mounting bracket (7) and uses stereo vision technology to collect multi-angle images of the component to be repaired. The industrial computer runs an image recognition algorithm to extract the three-dimensional coordinates, posture angle, and surface features of the target component. The processed data is fed back to a programmable logic controller for planning the motion path and grasping strategy of the manipulator (807). The data acquisition system (400) includes a position sensor (19), an infrared laser sensor (20), a magnetostrictive displacement sensor (22), an encoder (23), a force sensor (24) and a data acquisition card; two start and stop sensing plates are installed at the bottom of the rotating table (2); the position sensor (19) monitors the position of the rotating table (2) in real time through the two sensing plates at the bottom of the rotating table (2), and controls the start and stop of the stepping motor (3) through the driver of the stepping motor (3); two infrared laser sensors (20) are respectively installed on both sides of the sliding support (4) to detect the moving distance of the moving platform (5), and determine the moving distance by controlling the running speed and direction of the linear motor (6). The movable platform (5) is ensured to be accurately positioned; the magnetostrictive displacement sensor (22) is installed on the first oil cylinder (808) and the second oil cylinder (8078) for real-time monitoring of the piston rod displacement of the two oil cylinders, thereby adjusting the grasping action and strength of the manipulator (807); the encoder (23) is installed on the shaft of the servo motor (10) for measuring the rotation angle and speed of the servo motor (10); the force sensor (24) is installed on the grasping part of the manipulator (807) for detecting the force applied when the manipulator (807) grasps the part to be repaired; the data acquisition card converts the sensor signals into digital signals and transmits them to the programmable logic controller for comprehensive analysis and control decision-making.

7. A calibration method for the control system according to claim 6, characterized in that: The following steps are involved: S1 Obtaining Standard Component Data: Based on the specific model of the mining roadheader, obtain the accurate size and shape data of each standard component of the corresponding model of the roadheader from the manufacturer to ensure the accuracy and adaptability of the standard component data used; S2: Place the standard component: Place the standard component associated with the acquired data within the working range of the disassembly device to provide calibration objects and working conditions for subsequent calibration operations; S3 binocular camera image acquisition and processing: The binocular camera (21) acquires image data of the standard component, transmits the acquired image data to the industrial computer, processes the image of the standard component using the image processing algorithm module, and calculates the actual position and posture data of the standard component in the image; S4 Binocular camera parameter adjustment: Compare the calculated actual position and posture data with the real position and posture data of the standard component to obtain position deviation and posture deviation data; Based on the position deviation and posture deviation data, adjust the focal length, aperture, and image acquisition angle parameters of the binocular camera (21) to reduce the deviation; S5: Grasping action data collection: start the servo motor (10), the first oil cylinder (808) and the second oil cylinder (8078), so that the manipulator (807) can grasp the standard component, and use the magnetostrictive displacement sensor (22), the encoder (23) and the force sensor (24) to collect data in real time; S6 Control Algorithm Parameter Adjustment: Compare the collected sensor data with the theoretical data of the grasping action of the standard component, and adjust the proportional coefficient, integral coefficient, and differential coefficient in the PID control algorithm based on the comparison results; S7 repeats the calibration until the standard is met: repeat steps 3 to 6 times until the deviation between the position data calculated after processing the image data collected by the binocular camera (21) and the actual data is controlled within ±3 mm, the deviation between the posture data and the actual data is controlled within ±1°, and at the same time, the deviation between the data collected by the magnetostrictive displacement sensor (22) and the theoretical displacement data of the grasping action is controlled within ±1 mm, the deviation between the data collected by the force sensor (24) and the theoretical grasping force data of the grasping action is controlled within ±8% of the grasping force, the deviation between the angle in the data collected by the encoder (23) and the theoretical rotation angle data is controlled within ±0.3°, and the deviation between the speed and the rated speed data is controlled within ±3% of the rated speed, thus completing the calibration of the multi-directional adaptive disassembly device of the mining tunneling machine.

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