Roadway advanced unit support attitude monitoring control system and method

Abstract

The invention provides a roadway advanced unit support attitude monitoring control system and method, and belongs to the technical field of roadway advanced unit support attitude monitoring control. The technical problem to be solved is to provide the system and the method for monitoring and controlling the attitude of the roadway advanced unit bracket. According to the technical scheme, a support controller, an electro-hydraulic directional control valve, an electromagnetic driver and an automatic backwashing filter are arranged on a base of each unit support; double-shaft tilt angle sensors are arranged on a top beam, a base and a waste rock blocking plate of each unit support, and a stroke sensor is arranged in a stand column of each unit support; a pressure sensor is arranged at the bottom of the upright post of each unit bracket; the front end and the middle part of the lower side of each unit bracket are respectively provided with an infrared distance measuring sensor; the tail end of each unit bracket and the middle part of the upper side are respectively provided with an infrared receiving device; the method is applied to monitoring and control of the attitude of the roadway advanced unit support.

Description

Technical Field

[0001] The invention provides a tunnel advance unit support posture monitoring control system and method, belonging to the technical field of tunnel advance unit support posture monitoring control. Background Art

[0002] In coal mining, the tunnel advance unit support is an important supporting equipment in the tunnel working face. The stability and accuracy of its posture adjustment will be directly related to the overall safety of the tunnel.

[0003] However, in the actual application environment of unit supports, due to the complexity of geological conditions and the dynamic nature of support operations, the overall tunnel often has an undulating shape. It is often difficult to identify the degree of change in the support posture using traditional manual monitoring methods, especially when there are slight changes in the support posture, it cannot be detected in time, which will lead to safety hazards in the entire support operation and is prone to low-quality collapse and losses. It is difficult to meet the needs of efficient and accurate safety support. Summary of the invention

[0004] In order to overcome the deficiencies in the prior art, the present invention aims to solve the technical problem of providing a tunnel advance unit support posture monitoring control system and method.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is: a tunnel advance unit support posture monitoring and control system, comprising a plurality of unit supports arranged side by side, and a support controller, an electro-hydraulic reversing valve, an electromagnetic driver, and an automatic backwashing filter are arranged on the base of each unit support; Dual-axis inclination sensors are installed on the top beam, base and rock baffle of each unit support to measure the inclination attitude data of the support and the rock baffle attitude data; A travel sensor is arranged inside the column of each unit support to measure the travel data of the column and obtain the height data of the unit support; A pressure sensor is provided at the bottom of the column of each unit support to measure the pressure data of the lower cavity of the column; An infrared distance measuring sensor is respectively arranged at the front end and the middle part of the lower side of each unit bracket; An infrared receiving device is respectively arranged at the end of each unit bracket and the middle of the upper side; It also includes an iGPS rotating transmitter arranged in front of the first unit support and in the middle of the tunnel top plate, and an iGPS signal receiver arranged at the front end of the first unit support; The support controller is electrically connected to the electro-hydraulic reversing valve, the electromagnetic driver, the automatic backwashing filter, the dual-axis inclination sensor, the stroke sensor, the pressure sensor, the infrared ranging sensor, the infrared receiving device, the iGPS rotation transmitter, and the iGPS signal receiver through wires; It also includes a monitoring server arranged on the ground and in the chute centralized control center, and the monitoring server is connected to the communication port of the support controller through a wire.

[0006] It also includes a power module arranged on the unit bracket, and the power input end of the bracket controller is connected to the power module.

[0007] A method for monitoring and controlling a tunnel advance unit support posture monitoring and control system includes the following monitoring and control steps: Step 1: Sort and name each unit bracket set in the lane, where: The row of unit brackets close to the upper side of the lane is named the first unit bracket, the third unit bracket, the fifth unit bracket... The row of unit supports close to the lower side of the tunnel is named the second unit support, the fourth unit support, the sixth unit support, etc. Step 2: Monitor the position and posture of the first unit bracket and the third unit bracket, and set the position of the iGPS rotating transmitter as the origin of the lane coordinate system O r Location, O r X is the center line of the tunnel pointing to the direction of the mining face, O r Y is the vertical direction of the tunnel longitudinal section pointing to the lower wall, O r Z is the direction from the origin to the ground; Step 3: Obtain the horizontal distance L1 and the straight-line distance L7 between the iGPS rotating transmitter and the iGPS signal receiver installed on the first unit bracket, and at the same time obtain the horizontal angle R1 and the vertical angle R7 of the iGPS rotating transmitter relative to the iGPS signal receiver installed on the first unit bracket, and combine the origin height H1 of the fixed position of the first unit bracket to calculate the specific position data O1 of the first unit bracket in the three-dimensional coordinate system of the lane r , the calculation formula is: ; Step 4: Similarly, calculate and obtain the corresponding position data O2 of the second unit bracket r ; Step 5: Obtain the horizontal distance L2 and the straight-line distance L8 between the infrared receiving device set at the end of the first unit support base and the infrared ranging sensor set at the front end of the third unit support base, and at the same time obtain the horizontal angle R2 and the vertical angle R8 of the infrared receiving device set at the end of the first unit support base relative to the infrared ranging sensor set at the front end of the third unit support base, and combine the origin height H1 of the fixed position of the third unit support, by calculating the position and posture of the third unit support relative to the first unit support, obtain the specific position data O3 of the third unit support in the three-dimensional coordinate system of the lane r , the calculation formula is: ; Step 6: Obtain the horizontal distance L3 between the infrared receiving device in the middle of the first unit bracket base and the infrared ranging sensor in the middle of the second unit bracket base, and at the same time obtain the horizontal angle R3 of the infrared receiving device in the middle of the first unit bracket base relative to the infrared ranging sensor in the middle of the second unit bracket base, and perform filtering fusion and data calibration in combination with the collected data and calculated data; Step 7: Repeat data collection to obtain three-point position data of the unit support position and posture. By connecting the three points of the three-point data and taking the center position of the triangle, the specific position of the unit support in the three-dimensional coordinate system of the lane is obtained. The monitoring server builds a model based on the position data, and displays the position and posture values ​​of each unit support in real time through the model; Step 8: The monitoring server issues an alarm or runs an automatic adjustment program based on the real-time position and posture values ​​of each unit bracket.

[0008] The specific method of step eight is: The operation monitoring server sets the posture change threshold to alarm or run the automatic adjustment program. The specific rules are as follows: Set an alarm when the unit bracket's own posture base angle exceeds 12°, and emergency stop when it exceeds 15°, and perform manual intervention; When the angle of the top beam of the unit support exceeds 12° and the pressure value collected by the pressure sensor is in a decompression state, an alarm is issued and the column is controlled to automatically replenish pressure. When it exceeds 15°, an emergency stop is made and manual intervention is performed; Set 90% and 40% of the pressure sensor's calibrated pressure as the threshold. If it exceeds 90%, it is overpressure, and if it is less than 40%, it is underpressure, both of which trigger an alarm; When the inclination angle of the rock retaining plate exceeds 15°, an alarm is set to sound and the rock retaining jack is controlled to automatically add pressure.

[0009] The beneficial effects of the present invention compared with the prior art are as follows: the tunnel advance unit support posture monitoring and control scheme provided by the present invention realizes real-time monitoring and dynamic adjustment of the support posture by integrating the sensing system, the data processing system and the actuator, thereby ensuring the stability and safety of the support under complex geological conditions and improving the support efficiency. It can realize automatic monitoring and adjustment of the support posture, reduce the physical burden and labor intensity of personnel, and can timely detect and warn of abnormal support posture, avoid safety accidents caused by support failure, and improve the safety of tunnel operations; the present invention can continuously optimize the support strategy and further improve the support effect and tunnel stability by analyzing and processing the collected data. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present invention will be further described below in conjunction with the accompanying drawings: Figure 1 It is a flow chart of the steps of the lane advance unit support posture monitoring and control method of the present invention; Figure 2 It is a structural schematic diagram of the tunnel advance unit support posture monitoring and control system of the present invention; Figure 3 It is a schematic diagram of the structure of the electro-hydraulic control system of the lane advance unit support in an embodiment of the present invention; Figure 4 It is a schematic diagram of the installation structure of the tunnel advance unit support posture monitoring and control system of the present invention; Figure 5 It is a simulation schematic diagram of the position change of the system in the top-down viewing direction in an embodiment of the present invention; Figure 6 It is a simulation schematic diagram of the position change of the system in the normal viewing direction in an embodiment of the present invention; The meanings of the serial numbers in the figure are: 1 is the top beam, 2 is the base, 3 is the column, 4 is the side support jack, 5 is the side support seat, 6 is the gangue baffle plate, 7 is the gangue baffle jack, 8 is the bracket controller, 9 is the electro-hydraulic reversing valve, 10 is the electromagnetic drive, 11 is the automatic backwashing filter, 12 is the dual-axis inclination sensor, 13 is the stroke sensor, 14 is the pressure sensor, 15 is the infrared ranging sensor, 16 is the infrared receiving device, 17 is the iGPS rotation transmitter, and 18 is the iGPS signal receiver. DETAILED DESCRIPTION

[0011] like Figures 1 to 6 As shown, the present invention provides a monitoring and control solution for the posture of the tunnel advance unit support. The solution realizes real-time monitoring and dynamic adjustment of the support posture by integrating sensors, data processing systems, intelligent control algorithms and actuators, thereby ensuring the stability and safety of the support under complex geological conditions and improving the efficiency of tunnel support.

[0012] To achieve the above-mentioned purpose, the monitoring and control system provided by the present invention is specifically installed on the tunnel advance unit bracket, wherein the unit bracket includes a top beam, a base, a column, a side support jack, and a side support seat, and a gangue retaining plate and a gangue retaining jack are also arranged on the upper side of the bracket; each tunnel advance unit bracket is installed with a set of electro-hydraulic control devices, and the electro-hydraulic control device includes a power module, a bracket controller, an electromagnetic driver, an electro-hydraulic reversing valve, an automatic backwash filter and a corresponding sensing module; in addition, a monitoring server is also arranged on the ground and in the chute control center, and a man-machine operation interface is built in the monitoring server, which can perform posture monitoring, data analysis and remote control of the actions of the tunnel advance unit bracket.

[0013] Furthermore, the above-mentioned bracket controller, electromagnetic driver, electro-hydraulic reversing valve, and automatic backwashing filter are each provided at a suitable position of each unit bracket; each power supply module is provided to support power supply for the electronic control systems of six unit brackets at the same time.

[0014] Furthermore, the above-mentioned perception module includes a dual-axis inclination sensor, a stroke sensor, a pressure sensor, an infrared ranging sensor and a receiving device; wherein 2-3 dual-axis inclination sensors are arranged on each frame, which can be respectively arranged at appropriate positions on the base, the top beam and the rock baffle plate, for measuring the inclination posture of the bracket and the rock baffle plate posture; one stroke sensor is arranged on each frame, which is arranged inside the left column, for measuring the stroke of the column and obtaining the height of the bracket; one pressure sensor is arranged on each frame, which is arranged on the left column, for measuring the pressure in the lower cavity of the column; in addition, an infrared ranging sensor is arranged at the front end of each frame (not used for the first frame), an infrared receiving device is arranged at the end of each frame (not used for the tail frame), an infrared ranging sensor is arranged in the middle of the lower side bracket, and an infrared receiving device is arranged in the middle of the upper side bracket.

[0015] Furthermore, an iGPS rotating transmitter is separately arranged in front of the first unit support and at a suitable position in the middle of the tunnel roof, and an iGPS signal receiver is also arranged at the front end of the first unit support.

[0016] Furthermore, the built-in human-machine interface of the monitoring server builds a bracket posture mapping system based on the software platform, selects the position of the iGPS rotating transmitter in the platform world coordinate system as the origin of the three-dimensional coordinate system, and determines the directions of each coordinate axis of the tunnel coordinate system to realize the establishment of the coordinate system in the host computer program; when in use, the distance and angle information obtained by the perception module (various sensors) is used to realize the posture monitoring of the tunnel advance bracket, and through the pre-set threshold of the posture change, it is compared with the posture data collected by the monitoring, and timely alarm is issued or the automatic adjustment program is run.

[0017] like Figures 1 to 6As shown, in an embodiment of the present invention, a tunnel advance unit support posture monitoring and control system is provided, wherein each unit support installed and used in the tunnel includes: a top beam 1, a base 2, a column 3, a side support jack 4, and a side support seat 5. A gangue baffle plate 6 and a gangue baffle jack 7 are also provided on the upper side of the support. The present invention installs a set of electro-hydraulic control devices on each unit support, and the electro-hydraulic control device includes: a power module, a support controller 8, an electro-hydraulic reversing valve 9, an electromagnetic driver 10, an automatic backwashing filter 11 and a corresponding sensing module; in the human-machine operation interface of the monitoring server, the action of each unit support in the tunnel can be monitored, data analyzed and remotely controlled; during installation, a support controller 8, an electromagnetic driver 10, an electro-hydraulic reversing valve 9 and an automatic backwashing filter 11 are respectively provided at a suitable position of the base of each unit support; The sensing module includes: a dual-axis tilt sensor 12, a stroke sensor 13, a pressure sensor 14, an infrared ranging sensor 15, and an infrared receiving device 16; 2-3 dual-axis tilt sensors 12 are installed on each unit bracket, specifically arranged at appropriate positions on the base 2, the top beam 1 and the baffle plate 6 of the unit bracket, and are used to measure the tilt posture of the bracket and the posture of the baffle plate 6; one stroke sensor 13 is installed on each unit bracket, and is arranged inside the left column of the unit bracket, and is used to measure the column stroke and obtain the bracket height; when in use, by obtaining the top beam 1, the base 2, the baffle plate 6 ... The two-way angle data of plate 6 and the stroke data of column 3 are used to complete the monitoring of the posture of the unit bracket itself; the pressure sensor 14 is installed on each unit bracket, and is also set at the bottom of the left column to measure the lower cavity pressure of the bracket column; and an infrared ranging sensor 15 is set at the front end of each unit bracket (not used for the first bracket), and an infrared receiving device 16 is set at the end of each unit bracket (not used for the tail bracket). At the same time, an infrared ranging sensor 15 is set in the middle of the lower side of the unit bracket, and an infrared receiving device 16 is set in the middle of the upper side of the unit bracket.

[0018] In order to realize real-time monitoring of the support posture, the present invention also arranges an iGPS rotating transmitter 17 at a suitable position in front of the first unit support and in the middle of the tunnel roof, and arranges an iGPS signal receiver 18 correspondingly at the front end of the first unit support; specifically, a support posture mapping system is constructed in the human-machine operation interface, the position of the iGPS rotating transmitter 17 is selected as the origin of the three-dimensional coordinate system in the coordinate system, and the directions of the coordinate axes of the tunnel coordinate system are determined to complete the establishment of the coordinate system.

[0019] In the embodiment of the present invention, taking the monitoring of the position and posture of the first unit bracket and the third unit bracket as an example, the monitoring server sets the position of the iGPS rotating transmitter as the origin of the lane coordinate system O r Location, Or X is the center line of the tunnel pointing to the direction of the mining face, O r Y is the vertical direction of the tunnel longitudinal section pointing to the lower wall, O r Z is the origin pointing to the ground.

[0020] The distances L1, L7, angles R1, R7 obtained by the iGPS rotating transmitter and the iGPS signal receiver are combined with the origin height H1 of the fixed position of the first unit bracket to calculate the specific position O1 of the first unit bracket in the three-dimensional coordinate system of the lane. r , the expression is: ; Similarly, the position O2 corresponding to the second unit bracket can be obtained r ; The distances L2, L8, angles R2, R8 obtained by the infrared receiving device 16 at the end of the first unit support base and the infrared ranging sensor 15 at the front end of the third unit support base are combined with the origin height H1 of the fixed position of the third unit support to calculate the position and posture of the third unit support relative to the first unit support, and calculate the specific position O3 of the third unit support in the three-dimensional coordinate system of the lane. r , the expression is: ; Then, the distance L3 and angle R3 obtained by the infrared receiving device 16 in the middle of the base of the first unit bracket and the infrared ranging sensor 15 in the middle of the base of the second unit bracket are filtered, fused and calibrated in combination with the sensor perception data and calculation data. The data collection is repeated three times, and the data with a single floating value that affects the result exceeding 50mm is re-collected until the floating value of the data is within 20mm for three consecutive times (the program is set to repeat the data collection for an upper limit of 20 times and the alarm value is required when the alarm value is reached). The three-point position of the bracket position and posture is obtained, and the specific position of the third unit bracket in the three-dimensional coordinate system of the lane is obtained by connecting the three points of the three-time data and taking the center position of the triangle; finally, through the simple model modeling in the human-computer interaction interface of the centralized control center, the posture values ​​of the brackets at each position are displayed in real time to complete the position and posture monitoring of the brackets.

[0021] In order to realize the alarm and self-adjustment functions, the present invention pre-sets the attitude change threshold through the operation monitoring server, and makes timely alarms or runs the automatic adjustment program. At the same time, the electro-hydraulic control of the bracket action is realized through the human-machine operation interface and the bracket controller; in actual operation, the bracket's own attitude base angle is specifically set to alarm when it exceeds 12°, and emergency stop requires manual intervention when it exceeds 15°; the top beam angle is set to exceed 12°, and the pressure value of the pressure sensor is in a depressurized state, then an alarm is issued and the column is automatically pressurized, and emergency stop requires manual intervention when it exceeds 15°; 90% and 40% of the calibrated pressure of the pressure sensor are set as thresholds, exceeding 90% is overpressure, and below 40% is depressurization, both of which trigger alarms; the inclination angle of the rock retaining plate is set to exceed 15° for automatic pressure replenishment and alarm of the rock retaining jack.

[0022] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A tunnel advance unit support posture monitoring and control system, comprising a plurality of unit supports arranged side by side, characterized in that: A support controller (8), an electro-hydraulic reversing valve (9), an electromagnetic driver (10), and an automatic backwashing filter (11) are arranged on the base (2) of each unit support; A dual-axis inclination sensor (12) is provided on the top beam (1), the base (2) and the rock baffle plate (6) of each unit support, and is used to measure support inclination attitude data and rock baffle plate attitude data; A stroke sensor (13) is arranged inside the column (3) of each unit support, and is used to measure the stroke data of the column (3) and obtain the height data of the unit support; A pressure sensor (14) is provided at the bottom of the column (3) of each unit support, and is used to measure the pressure data of the lower cavity of the column (3); An infrared distance measuring sensor (15) is respectively arranged at the front end and the middle part of the lower side of each unit bracket; An infrared receiving device (16) is respectively arranged at the end of each unit bracket and the middle of the upper side; It also includes an iGPS rotating transmitter (17) arranged in front of the first unit support and in the middle of the tunnel roof, and an iGPS signal receiver (18) arranged at the front end of the first unit support; The support controller (8) is electrically connected to the electro-hydraulic reversing valve (9), the electromagnetic driver (10), the automatic backwashing filter (11), the dual-axis inclination sensor (12), the stroke sensor (13), the pressure sensor (14), the infrared distance sensor (15), the infrared receiving device (16), the iGPS rotation transmitter (17), and the iGPS signal receiver (18) through wires; It also includes a monitoring server arranged on the ground and in the chute centralized control center, the monitoring server being connected to the communication port of the support controller (8) via a wire.

2. A tunnel advance unit support posture monitoring and control system according to claim 1, characterized in that: It also includes a power module arranged on the unit bracket, and the power input end of the bracket controller (8) is connected to the power module.

3. The method for monitoring and controlling the posture monitoring and control system of a lane advance unit support according to claim 1 is characterized in that: The monitoring and control steps include the following: Step 1: Sort and name each unit bracket set in the lane, where: The row of unit brackets close to the upper side of the lane is named the first unit bracket, the third unit bracket, the fifth unit bracket... The row of unit supports close to the lower side of the tunnel is named the second unit support, the fourth unit support, the sixth unit support, etc. Step 2: Monitor the position and posture of the first unit bracket and the third unit bracket, and operate the monitoring server to set the position of the iGPS rotating transmitter (17) as the origin of the lane coordinate system O r Location, O r X is the center line of the tunnel pointing to the direction of the mining face, O r Y is the vertical direction of the tunnel longitudinal section pointing to the lower wall, O r Z is the direction from the origin to the ground; Step 3: Obtain the horizontal distance L1 and the linear distance L7 between the iGPS rotating transmitter (17) and the iGPS signal receiver (18) installed on the first unit bracket, and at the same time obtain the horizontal angle R1 and the vertical angle R7 of the iGPS rotating transmitter (17) relative to the iGPS signal receiver (18) installed on the first unit bracket, and combine the origin height H1 of the fixed position of the first unit bracket to calculate the specific position data O1 of the first unit bracket in the three-dimensional coordinate system of the lane r , the calculation formula is: ； Step 4: Similarly, calculate and obtain the corresponding position data O2 of the second unit bracket r ; Step 5: Obtain the horizontal distance L2 and the straight-line distance L8 between the infrared receiving device (16) provided at the end of the base of the first unit support and the infrared ranging sensor (15) provided at the front end of the base of the third unit support, and at the same time obtain the horizontal angle R2 and the vertical angle R8 of the infrared receiving device (16) provided at the end of the base of the first unit support relative to the infrared ranging sensor (15) provided at the front end of the base of the third unit support, and combine the origin height H1 of the fixed position of the third unit support, by calculating the position and posture of the third unit support relative to the first unit support, obtain the specific position data O3 of the third unit support in the three-dimensional coordinate system of the lane r , the calculation formula is: ； Step 6: Obtain the horizontal distance L3 between the infrared receiving device (16) in the middle of the base of the first unit support and the infrared ranging sensor (15) in the middle of the base of the second unit support, and simultaneously obtain the horizontal angle R3 of the infrared receiving device (16) in the middle of the base of the first unit support relative to the infrared ranging sensor (15) in the middle of the base of the second unit support, and perform filtering fusion and data calibration in combination with the collected data and the calculated data; Step 7: Repeat data collection to obtain three-point position data of the unit support position and posture. By connecting the three points of the three-point data and taking the center position of the triangle, the specific position of the unit support in the three-dimensional coordinate system of the lane is obtained. The monitoring server builds a model based on the position data, and displays the position and posture values ​​of each unit support in real time through the model; Step 8: The monitoring server issues an alarm or runs an automatic adjustment program based on the real-time position and posture values ​​of each unit bracket.

4. The method for monitoring and controlling the posture monitoring and control system of a lane advance unit support according to claim 3 is characterized in that: The specific method of step eight is: The operation monitoring server sets the posture change threshold to alarm or run the automatic adjustment program. The specific rules are as follows: Set an alarm when the unit bracket's own posture base angle exceeds 12°, and emergency stop when it exceeds 15°, and perform manual intervention; When the angle of the top beam of the unit support exceeds 12° and the pressure value collected by the pressure sensor is in a decompression state, an alarm is issued and the column is controlled to automatically replenish pressure. When it exceeds 15°, an emergency stop is made and manual intervention is performed; Set 90% and 40% of the pressure sensor's calibrated pressure as the threshold. If it exceeds 90%, it is overpressure, and if it is less than 40%, it is underpressure, both of which trigger an alarm; When the inclination angle of the rock retaining plate exceeds 15°, an alarm is set to sound and the rock retaining jack is controlled to automatically add pressure.

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