Modularized design method for electro-hydraulic control reversing valve group of mining hydraulic support

Abstract

The invention discloses a modular design method for an electro-hydraulic control reversing valve group of a mining hydraulic support, which comprises the following steps of: 1, designing a modular layered architecture, and splitting the valve group into independent functional modules; step 2, standardized joint design; 3, performing hot plug design, and embedding a power supply isolation circuit in the valve group control unit; 4, multi-valve-group collaborative design is carried out, CAN bus networking is adopted, and action time sequences and pressure parameters of all valve groups are synchronized; step 5, environment adaptation testing; functional decoupling and redundancy control are realized through a modular layered architecture, the interface compatibility and the disassembly and assembly efficiency are improved by combining a standardized quick-change connector and a CAN bus protocol, the maintenance shutdown risk is reduced by adopting a hot-plug power supply isolation technology, the system synchronization precision is enhanced by depending on multi-valve-group cooperative control, and the system reliability is improved. The problems that traditional equipment is poor in expansibility, low in cooperation precision, slow in fault recovery and the like are solved while continuous and stable operation of the hydraulic system is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of coal mine automation, and particularly to a modular design method for electro-hydraulic control reversing valve groups of mine hydraulic supports. Background Art

[0002] The electro-hydraulic control reversing valve of a mine hydraulic support is a core control component in the mine hydraulic support system, mainly used to precisely adjust the flow direction of hydraulic oil through electrical signals, thereby controlling the lifting, pushing and other actions of the support. It usually consists of an electromagnet, a valve body, a valve core and seals, etc. After receiving the electrical signal, the electromagnet drives the valve core to move, changing the oil passage. The electrical signal controls the action of the electromagnet, pushes the valve core to displace, switches the flow direction of the hydraulic oil, enables the hydraulic cylinder to perform extension or retraction operations, and then adjusts the state of the support.

[0003] The traditional design of electro-hydraulic control reversing valve groups for mine hydraulic supports has problems such as low integration, single function and difficult maintenance. The valve body and the electromagnetic drive unit are fixedly connected. During a failure, the whole unit needs to be disassembled, and the maintenance efficiency is low. Special valve groups need to be customized for different working conditions, with poor function expandability and high upgrade costs. The harsh underground environment easily causes valve core jamming or seal failure. However, the traditional valve group lacks rapid replacement and anti-pollution designs and is difficult to meet the requirements of high-frequency and high-reliability fully mechanized mining operations. Therefore, the present invention proposes a modular design method for electro-hydraulic control reversing valve groups of mine hydraulic supports to solve the problems existing in the prior art. Summary of the Invention

[0004] Aiming at the above problems, the purpose of the present invention is to propose a modular design method for electro-hydraulic control reversing valve groups of mine hydraulic supports. This modular design method for electro-hydraulic control reversing valve groups of mine hydraulic supports realizes function decoupling and redundant control through a modular hierarchical architecture, improves interface compatibility and disassembly and assembly efficiency by combining standardized quick-change joints and CAN bus protocols, reduces the risk of maintenance downtime by using hot-swap power isolation technology, enhances the system synchronization accuracy by relying on multi-valve group collaborative control, and is supplemented by an IP67 protection level and extreme environment tests, significantly improving the maintainability, environmental adaptability and system reliability of the valve group. While ensuring the continuous and stable operation of the hydraulic system, it effectively solves the problems of poor expandability, low collaborative accuracy and slow fault recovery of traditional equipment, and can meet the high-efficiency operation and maintenance requirements in complex industrial scenarios.

[0005] To achieve the purpose of the present invention, the present invention is realized through the following technical solutions: A modular design method for electro-hydraulic control reversing valve groups of mine hydraulic supports, comprising the following steps:

[0006] Step 1, Modular hierarchical architecture design, splitting the valve group into independent functional modules;

[0007] Step 2: Standardized connector design. Set standard quick-change hydraulic connectors and plug-in electrical connectors on the basic valve body module to ensure oil circuit sealing and quick disassembly and assembly. The inlet and outlet oil ports of the valve body adopt a symmetrical layout to adapt to different installation directions, and the connectors are equipped with anti-misoperation mechanisms inside.

[0008] Step 3: Hot-swap design. Embed a power isolation circuit in the valve group control unit to allow the replacement of electromagnetic drive or function expansion modules under live conditions.

[0009] Step 4: Multi-valve group collaborative design. Use CAN bus networking to synchronize the action timing and pressure parameters of each valve group.

[0010] Step 5: Environmental adaptability test. Adopt a sealed design for the function modules and conduct IP67 dust and waterproof tests, plugging and unplugging life tests, and thermal cycling tests.

[0011] The further improvement lies in that: in Step 1, the function modules include a basic valve body module, an electromagnetic drive module, and a function expansion module. The basic valve body module serves as the core carrier, integrating a valve core, an oil passage, and a quick-change connector. The electromagnetic drive module is encapsulated with an electromagnet, a drive circuit, and a signal connector. The function expansion module is configured with a sensor unit, a communication unit, and a redundant control unit.

[0012] The further improvement lies in that: the basic valve body module adopts an aluminum alloy one-piece cast valve body, the valve core adopts a stepped structure, and redundant sealing rings are provided at both ends of the valve core.

[0013] The further improvement lies in that: in Step 2, the standard quick-change hydraulic connectors comply with ISO 6149 standard, and the electrical connectors unify the power supply, signal, and communication pin protocols, and the communication protocol is CAN bus.

[0014] The further improvement lies in that: in Step 2, the anti-misoperation mechanism is an asymmetric keyway structure between the plug and the socket, and the key width deviation is ±0.2 mm.

[0015] The further improvement lies in that: in Step 3, the power isolation circuit adopts an isolation circuit combined with PMOS + NMOS, which supports arc suppression during hot plugging.

[0016] The further improvement lies in that: in Step 5, the IP67 dust and waterproof test is to place in a dust box for 8 hours and soak in a water tank with a water depth of 1 m for 30 minutes.

[0017] The further improvement lies in that: in Step 5, the thermal cycling test is to cycle 20 times between -30°C and 80°C, and the seals have no cracking.

[0018] The beneficial effects of the present invention are as follows: The present invention realizes function decoupling and redundancy control through a modular hierarchical architecture, improves interface compatibility and disassembly and assembly efficiency by combining standardized quick-change joints and the CAN bus protocol, reduces the risk of maintenance downtime by adopting hot-swap power isolation technology, enhances the system synchronization accuracy by relying on multi-valve group collaborative control, and is supplemented by an IP67 protection level and extreme environment tests, significantly improving the maintainability, environmental adaptability and system reliability of the valve group. While ensuring the continuous and stable operation of the hydraulic system, it effectively solves the problems of poor scalability, low collaborative accuracy and slow fault recovery of traditional equipment, and can meet the high-efficiency operation and maintenance requirements in complex industrial scenarios. Description of the Drawings

[0019] Figure 1 It is a flowchart of the steps of the present invention. Detailed Embodiment

[0020] To deepen the understanding of the present invention, the present invention will be further described in detail below in conjunction with embodiments. These embodiments are only used to explain the present invention and do not constitute a limitation on the protection scope of the present invention.

[0021] The electro-hydraulic control reversing valve group of the mining hydraulic support is the core control component of the fully-mechanized coal mining equipment. Its performance directly determines the response speed, action accuracy and system reliability of the hydraulic support. In traditional valve groups, components such as valve bodies, electromagnetic drive units and sensors are welded or bolted together. When a fault occurs, the whole needs to be disassembled, which takes a long time for underground maintenance, may lead to the scrapping of the whole valve, increase the cost of spare part replacement, and requires the re-design of special valve groups for different coal mining working conditions, with a long R & D cycle and the inability to reuse existing modules. Traditional valve groups lack standardized interfaces. Adding sensors or communication units requires modifying the valve body structure, resulting in an increase in upgrade costs. Traditional O-ring seals are prone to aging in the high-dust and high-humidity underground environment. The integrated design of traditional valve groups can no longer meet the urgent needs of modern mines for high efficiency, reliability and intelligence. The introduction of modular technology provides a systematic solution for improving the reliability of hydraulic supports and optimizing the full-life cycle cost through three major innovations: function decoupling, interface standardization and intelligent collaboration, and has become an inevitable choice for the upgrade of mining equipment. The CAN FD protocol is a communication protocol upgraded based on the traditional CAN bus, aiming to solve the limitations of the classic CAN in data transmission rate and data volume. The ISO 6149 standard is a special standard formulated by the International Organization for Standardization (ISO) for threaded ports and joints used in hydraulic transmission systems, mainly specifying the interface design and performance requirements for metal-to-metal seals in hydraulic systems, and unifying the power, signal and communication pin protocols for electrical connectors.

[0022] Embodiment 1

[0023] Based on this, according to Figure 1 shown, this embodiment provides a modular design method for the electro-hydraulic control reversing valve group of the mining hydraulic support, including the following steps:

[0024] Step 1: Modular hierarchical architecture design, splitting the valve group into independent functional modules;

[0025] The functional modules include a basic valve body module, an electromagnetic drive module, and a function expansion module. By splitting the valve group into a basic valve body, an electromagnetic drive, and a function expansion module, functional decoupling and redundant design are achieved, solving the problems of difficult maintenance and poor scalability of traditional valve groups. The basic valve body module, as the core carrier, integrates a valve core, an oil passage, and a quick-change joint. The electromagnetic drive module encapsulates an electromagnet, a drive circuit, and a signal joint. The function expansion module is configured with a sensor unit, a communication unit, and a redundant control unit. The sensor unit internally has a piezoelectric pressure sensor and a Hall displacement sensor. The communication unit is equipped with the CAN FD protocol. By flexibly switching the rate and expanding the data capacity, the real-time performance and data throughput capacity of the industrial control system are significantly improved. In complex working conditions such as mine hydraulic supports, the combination of its high reliability, large bandwidth characteristics, and modular design, the redundant control unit provides a dual-MCU cross-check mechanism, and the modular design allows for the rapid replacement of faulty solenoid valves in a narrow space, avoiding the shutdown of the whole machine due to the damage of a single component. The redundant control unit ensures that when the main control chip fails in a high-temperature environment, the standby chip seamlessly takes over to ensure production continuity;

[0026] The basic valve body module uses an aluminum alloy integrally cast valve body, the valve core adopts a stepped structure, and redundant sealing rings are provided at both ends of the valve core. The aluminum alloy integral casting of the basic valve body and the stepped valve core structure improve the sealing reliability, and the independent electromagnetic drive module reduces the impact of electromagnetic faults on the core valve body.

[0027] Step 2: Standardized connector design. Set standard quick-change hydraulic connectors and plug-in electrical connectors on the basic valve body module to ensure oil circuit sealing and quick disassembly and assembly. The oil inlet and outlet of the valve body adopt a symmetrical layout to adapt to different installation directions, and an anti-misinsertion mechanism is built into the connector. The standard quick-change hydraulic connector complies with ISO 6149 standard, and the communication protocol is CAN bus. With its real-time performance, reliability, and topological flexibility, CAN bus has become the core communication technology in the field of industrial control. In harsh working conditions such as mine hydraulic supports, its multi-node coordination ability (such as ±5ms synchronous control) is deeply combined with the modular design concept, providing basic communication guarantee for the intelligent upgrade of complex electromechanical systems. The anti-misinsertion mechanism is an asymmetrical keyway structure between the plug and the socket, with a key width deviation of ±0.2mm. By using ISO 6149 standard quick-change hydraulic connectors and electrical connectors with a unified CAN bus protocol, combined with the anti-misinsertion keyway structure, it solves the problems of poor interface compatibility, limited installation direction, and risk of misinsertion, ensures oil circuit sealing and shortens the disassembly and assembly time, adapts to the rapid maintenance requirements under complex working conditions. The quick-change connector can still be quickly disassembled and assembled in a muddy environment, and the anti-misinsertion design prevents operators from misconnecting the oil pipes, resulting in abnormal system pressure. The unified electrical protocol supports the plug-and-play of different brand PLC controllers, reducing the equipment integration and debugging time.

[0028] Step 3: Hot-swap design. Embed a power isolation circuit in the valve group control unit to allow the replacement of electromagnetic drive or function expansion modules under live conditions. The power isolation circuit adopts an isolation circuit combined with PMOS + NMOS, supports arc suppression during hot plugging and unplugging, cuts off the signal circuit through an optocoupler isolator during the instant of plugging and unplugging, prevents electromagnetic interference from causing abnormal CAN bus communication, supports the replacement of modules under live conditions and suppresses plugging and unplugging arcs, solves the problem that traditional maintenance requires power-off, reduces the risk of production interruption, and at the same time protects the circuit from short circuits or arc damage.

[0029] Step 4: Multi-valve group coordination design. Use CAN bus networking to synchronize the action timing and pressure parameters of each valve group. Based on CAN bus networking, centralized synchronization of the action timing and pressure parameters of multiple valve groups is achieved, solving the problems of action delay and parameter deviation caused by decentralized control, and improving the system coordination accuracy, especially suitable for high-precision hydraulic synchronization scenarios.

[0030] Step 5: Environmental adaptability test. Adopt a sealed design for the functional modules and conduct IP67 dust and waterproof test, plugging and unplugging life test, and thermal cycling test. The IP67 dust and waterproof test is to place in a dust box for 8 hours and soak in a water tank with a depth of 1m for 30 minutes. The thermal cycling test is to cycle 20 times between -30°C and 80°C, and the seals are not cracked, ensuring the long-term reliability of the module in extreme temperature, humidity, and dust environments, and solving the problem of increased failure rate of traditional valve groups due to material deformation or seal failure.

[0031] Embodiment 2

[0032] When maintaining in a high-dust environment underground, with the system powered on, the operator presses the unlocking buckle of the electromagnetic drive module. The power supply circuit of this module is cut off through the PMOS+NMOS isolation circuit. The arc suppression circuit limits the current during plugging and unplugging to within 0.5A. The faulty module is withdrawn along the guide rail, and the pre-installed spare electromagnetic drive module is replaced. During plugging, the asymmetric keyway automatically corrects the orientation. After the module is in place, the CAN bus automatically identifies the new device ID, and the redundant control unit synchronizes the pressure parameter to the set value of 0.8MPa. The Hall sensor real-time feedbacks the spool displacement with an accuracy of ±0.1mm.

[0033] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. What is described in the above embodiments and the specification only illustrates the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements all fall within the scope of the present invention claimed. The scope of protection claimed by the present invention is defined by the appended claims and their equivalents.

Claims

1. A modular design method for an electro-hydraulic controlled directional valve group for a mining hydraulic support, characterized in that The following steps are involved: Step 1: Modular hierarchical architecture design, splitting the valve group into independent functional modules; Step 2: Standardized connector design: standard quick-change hydraulic connectors and plug-in electrical connectors are set on the basic valve body module to ensure the sealing of the oil circuit and quick disassembly and assembly. The inlet and outlet ports of the valve body are symmetrically arranged to adapt to different installation directions, and the connector has a built-in anti-fool mechanism; Step 3: Hot-swap design: embed the power isolation circuit in the valve group control unit to allow the replacement of the electromagnetic drive or function expansion module under power-on state; Step 4: Collaborative design of multiple valve groups, using CAN bus networking to synchronize the action timing and pressure parameters of each valve group; Step 5: Environmental adaptability test: adopt a sealed design for the functional module and perform IP67 dust and water resistance test, plug-in life test and hot and cold cycle test.

2. The modular design method of the electro-hydraulic controlled reversing valve group for a mining hydraulic support according to claim 1 is characterized in that: The functional module in step one includes a basic valve body module, an electromagnetic drive module and a functional expansion module. The basic valve body module serves as a core carrier and integrates a valve core, an oil channel and a quick-change connector. The electromagnetic drive module encapsulates an electromagnet, a drive circuit and a signal connector. The functional expansion module is configured with a sensor unit, a communication unit and a redundant control unit.

3. The modular design method of the electro-hydraulic controlled reversing valve group for a mining hydraulic support according to claim 2 is characterized by: The basic valve body module adopts an aluminum alloy integrally cast valve body, the valve core adopts a stepped structure, and redundant sealing rings are arranged at both ends of the valve core.

4. The modular design method of the electro-hydraulic controlled reversing valve group for a mining hydraulic support according to claim 1 is characterized in that: The standard quick-change hydraulic connector in step 2 complies with the ISO 6149 standard, and the electrical connector has unified power supply, signal and communication pin protocols, and the communication protocol is CAN bus.

5. The modular design method of the electro-hydraulic controlled reversing valve group for a mining hydraulic support according to claim 1 is characterized in that: The foolproof mechanism in step 2 is an asymmetric keyway structure between the plug and the socket, and the key width deviation is ±0.2mm.

6. The modular design method of the electro-hydraulic controlled reversing valve group for a mining hydraulic support according to claim 1 is characterized in that: The power isolation circuit in step three adopts a PMOS+NMOS combination isolation circuit, which supports arc suppression during live plugging and unplugging.

7. The modular design method of the electro-hydraulic controlled reversing valve group for a mining hydraulic support according to claim 1 is characterized in that: The IP67 dust and water resistance test in step 5 is to place the product in a dust box for 8 hours and immerse it in a 1m deep water tank for 30 minutes.

8. The modular design method of the electro-hydraulic controlled reversing valve group for a mining hydraulic support according to claim 1 is characterized by: The hot and cold cycle test in step 5 is a 20-cycle test at -30°C to 80°C, and there is no cracking of the sealing part.

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