Fault early-warning and intelligent decision-making system and method for large-diameter pipe-following drilling machine

Abstract

The invention provides a fault diagnosis and intelligent decision-making system and method.A hydraulic pump is further connected with a three-phase asynchronous motor, and the three-phase asynchronous motor is connected with a three-phase current detection sensor in a starting cabinet; the three-phase current detection sensor is connected with the input end of a signal conversion module in the starting cabinet; the output end of the signal conversion module is connected with the input end of a controller in the flameproof and intrinsically safe control cabinet for communication, and a stator side three-phase current signal of the three-phase asynchronous motor transmitted by the starting cabinet is read in real time; and the output end of the controller is respectively connected with the rotary electromagnetic valve and the feeding electromagnetic valve. According to the system, fault early warning, load identification and self-adaptive drilling decision making of the drilling machine in the construction process can be achieved. On the basis of existing hardware of a drilling machine electro-hydraulic system, on the premise that the coal safety requirement is met, the fault early warning and intelligent decision-making system of the large-diameter casing-following drilling machine is provided, and safe and efficient operation of the drilling machine is achieved.

Description

Technical Field

[0001] The present invention belongs to the technical field of drilling rigs, relates to emergency rescue, and particularly relates to a fault warning and intelligent decision-making system and method for a large-diameter pipe-following drilling rig. Background Art

[0002] Coal mines are mainly exploited underground. Once a coal mine accident occurs, it will cause the collapse of coal mine roadways and personnel to be trapped. According to statistics, 70% of the casualties are caused by the inability of personnel to be rescued in time after the roadway collapses. The collapsed roadway is a temporarily stable roadway formed by a pile body, and a dynamically stable lapping relationship is formed between each block. Rescuing in such a collapsed body is different from the original coal and rock mass. On the premise of ensuring the safety of rescue personnel, it is also necessary to improve the rescue speed and quickly rescue the trapped personnel inside the collapsed body. Using a large-diameter (450 mm) pipe-following rescue drilling rig to quickly construct a rescue passage is an effective rescue method.

[0003] In view of the requirement that the large-diameter rescue equipment operates stably and efficiently during the rescue process, the fault warning and intelligent decision-making of the operation parameters of the rescue drilling rig are of great significance to the rescue construction.

[0004] Due to the strict explosion-proof requirements for electrical equipment in coal mines, the types of sensing and detection components that can be used in coal mines are few, the design and development cost is high, and the application period for the safety standard of components is long. Summary of the Invention

[0005] Aiming at the deficiencies of the existing technology, the purpose of the present invention is to provide a fault warning and intelligent decision-making system and method for a large-diameter pipe-following drilling rig, so as to solve the technical problem that the emergency rescue ability of the large-diameter pipe-following drilling rig in the existing technology needs to be further improved.

[0006] To solve the above technical problems, the present invention is implemented by adopting the following technical solutions:

[0007] A fault diagnosis and intelligent decision-making system for a large-diameter pipe-following drilling rig, wherein the large-diameter pipe-following drilling rig includes a hydraulic pump, and the hydraulic pump drives a rotary load through a hydraulic motor; the hydraulic pump also drives a feeding load through a hydraulic cylinder.

[0008] The hydraulic pump is also connected to a three-phase asynchronous motor, and the three-phase asynchronous motor is connected to a three-phase current detection sensor inside the starting cabinet. The three-phase current detection sensor is used for collecting the stator-side phase current signal of the three-phase asynchronous motor.

[0009] The three-phase current detection sensor is connected to the input end of a signal conversion module inside the starting cabinet, and the signal conversion module is used for converting analog quantity into digital quantity.

[0010] The output end of the signal conversion module is connected to the input end of the controller inside the flameproof and intrinsically safe control cabinet for communication, and the three-phase current signals on the stator side of the three-phase asynchronous motor transmitted by the starting cabinet are read in real time.

[0011] The present invention also has the following technical features:

[0012] The three-phase current detection sensor includes three Hall current sensors, and the three Hall current sensors are respectively installed on the three-phase power supply introduction lines of the three-phase asynchronous motor.

[0013] The present invention also protects a fault diagnosis and intelligent decision-making method for a large-diameter pipe-following drill, and this method uses the large-diameter pipe-following drill fault diagnosis and intelligent decision-making system as described above.

[0014] This method includes the following steps:

[0015] Step 1, the three-phase current detection sensor collects the phase current signals on the stator side of the three-phase asynchronous motor.

[0016] Step 2, the collected phase current signals on the stator side of the three-phase asynchronous motor are transmitted to the controller through the 485 signal conversion module.

[0017] Step 3, perform clark coordinate transformation operation on the phase current signals on the stator side of the three-phase asynchronous motor.

[0018] Step 4, perform vector transformation between the phase currents i a , i b and i c on the stator side of the three-phase asynchronous motor and the two-phase perpendicular orthogonal currents i x and i y .

[0019] Step 5, respectively use i x as the horizontal axis and i y as the vertical axis to fuse and form a two-dimensional graph in the plane coordinate system and output it in the form of an image.

[0020] Step 6, use the prewitt operator to perform edge detection on the image output in Step 5, and extract the image edge point set.

[0021] Step 7, extract the circular trajectory as the base circle from the image edge point set extracted in Step 6 through the RHT detection algorithm.

[0022] Step 8, extract the radius R parameter of the base circle obtained in Step 7, perform linear transformation and logical correspondence between the radius R parameter of the base circle and the actual control physical quantity, and calculate the system load of the large-diameter pipe-following drill in real time.

[0023] According to the system load, the working parameters of the large-diameter pipe-following drill are determined, and the overflow thresholds of the rotation and feeding of the large-diameter pipe-following drill are adjusted in real time through the PWM output of the PID adjustment controller.

[0024] Step Nine: Calculate the distance R between the base circle coordinates obtained in Step Seven and the actual trajectory coordinates at the same moment. L , when R L is greater than the normal value, output the fault alarm information of the large-diameter pipe-following drill.

[0025] Compared with the prior art, the present invention has the following technical effects:

[0026] The system of the present invention can realize fault early warning, load identification and adaptive drilling decision-making during the construction process of the drill. Based on the existing hardware of the electro-mechanical-hydraulic system of the drill and meeting the requirements of coal mine safety, a fault early warning and intelligent decision-making system for a large-diameter pipe-following drill is proposed to realize the safe and efficient operation of the drill. Description of the Drawings

[0027] Figure 1 It is a schematic diagram of the overall structure of the fault diagnosis and intelligent decision-making system for a large-diameter pipe-following drill.

[0028] Figure 2 It is a schematic diagram of the flow of the fault diagnosis and intelligent decision-making method for a large-diameter pipe-following drill.

[0029] Figure 3 It is a schematic diagram of the electro-mechanical-hydraulic coupling model of a three-phase asynchronous motor - hydraulic pump rotor system.

[0030] The meanings of the various labels in the figure are as follows: 1 - large-diameter pipe-following drill, 2 - three-phase asynchronous motor, 3 - starting cabinet, 4 - three-phase current detection sensor, 5 - 485 signal conversion module, 6 - flameproof and intrinsically safe control cabinet, 7 - controller, 8 - rotation solenoid valve, 9 - feeding solenoid valve, 10 - coupling.

[0031] 101 - hydraulic pump, 102 - hydraulic motor, 103 - rotation load, 104 - hydraulic cylinder, 105 - feeding load.

[0032] The following further elaborates on the specific content of the present invention in conjunction with embodiments. Specific Embodiments

[0033] It should be noted that all modules, operations, operators and devices in the present invention, unless otherwise specified, all adopt the modules, operations, operators and devices known in the prior art.

[0034] Specific embodiments of the present invention are given below. It should be noted that the present invention is not limited to the following specific embodiments, and any equivalent transformation based on the technical solution of this application falls within the protection scope of the present invention.

[0035] Embodiment:

[0036] This embodiment provides a fault diagnosis and intelligent decision-making system for a large-diameter pipe-following drill rig, as Figure 1 shown. The large-diameter pipe-following drill rig 1 includes a hydraulic pump 101. The hydraulic pump 101 drives a rotary load 103 through a hydraulic motor 102; the hydraulic pump 101 also drives a feed load 105 through a hydraulic cylinder 104.

[0037] As Figure 1 shown, the hydraulic pump 101 is also connected to a three-phase asynchronous motor 2. The three-phase asynchronous motor 2 is connected to a three-phase current detection sensor 4 inside a starting cabinet 3. The three-phase current detection sensor 4 is used for collecting the stator-side phase current signals of the three-phase asynchronous motor 2.

[0038] As Figure 1 shown, the three-phase current detection sensor 4 is connected to the input end of a 485 signal conversion module 5 inside the starting cabinet 3. The 485 signal conversion module 5 is used for converting analog quantities into digital quantities.

[0039] As Figure 1 shown, the output end of the 485 signal conversion module 5 is connected to the input end of a controller 7 inside an explosion-proof and intrinsically safe control cabinet 6 for communication, and the stator-side three-phase current signals of the three-phase asynchronous motor 2 transmitted by the starting cabinet 3 are read in real time; the output end of the controller 7 is respectively connected to a rotary solenoid valve 8 and a feed solenoid valve 9.

[0040] In this embodiment, further, the output end of the controller 7 is respectively connected to the rotary solenoid valve 8 and the feed solenoid valve 9. The rotary solenoid valve 8 is connected to the hydraulic motor 102, and the feed solenoid valve 9 is connected to the hydraulic cylinder 104.

[0041] As a preferred solution of this embodiment, as Figure 1 shown, the three-phase current detection sensor (4) includes three Hall current sensors, and the three Hall current sensors are respectively installed on the three-phase power supply introduction lines of the three-phase asynchronous motor 2.

[0042] Embodiment 2:

[0043] This embodiment provides a fault diagnosis and intelligent decision-making method for a large-diameter pipe-following drill rig. This method uses the fault diagnosis and intelligent decision-making system for a large-diameter pipe-following drill rig given in Embodiment 1.

[0044] As Figure 2 shown, this method includes the following steps:

[0045] Step 1: The three-phase current detection sensor 4 collects the stator-side phase current signals of the three-phase asynchronous motor 2.

[0046] Step 2: The collected stator-side phase current signals of the three-phase asynchronous motor 2 are transmitted to the controller 7 through the 485 signal conversion module 5.

[0047] Step 3: Perform clark coordinate transformation operation on the stator-side phase current signals of the three-phase asynchronous motor 2.

[0048] Step 4: Perform vector transformation between the stator-side phase currents i a 、i b and i c of the three-phase asynchronous motor 2 and the two-phase perpendicular orthogonal currents i x and i y .

[0049] In Step 4, the vector transformation is:

[0050] That is:

[0051] The stator three-phase currents of the three-phase asynchronous motor 2 change according to the sine law, and the phase difference is 120°; assuming the three-phase currents are as follows:

[0052]

[0053] Through vector transformation, we get:

[0054]

[0055] In the formula:

[0056] I m represents the current amplitude;

[0057] ω represents the power supply frequency;

[0058] t represents time.

[0059] It can be seen that the curve formed by the fusion of the transformed i x and i y in the plane is a circular trajectory.

[0060] Step 5: Respectively, with i x as the horizontal axis and i y as the vertical axis, fuse in the plane coordinate system to form a two-dimensional graph and output it in the form of an image.

[0061] Step 6: Use the prewitt operator to perform edge detection on the image output in Step 5 and extract the image edge point set.

[0062] In this step, neighborhood convolution is performed on the image in the image space using two directional templates, one for detecting horizontal edges and the other for detecting vertical edges.

[0063] In step six, for the digital image f(x, y), the calculation method of the Prewitt operator is as follows:

[0064] G x = |[f(i - 1, j - 1) + f(i - 1, j) + f(i - 1, j + 1)] - [f(i + 1, j - 1) + f(i + 1, j) + f(i + 1, j + 1)]|;

[0065] G y = |[f(i - 1, j + 1) + f(i, j + 1) + f(i + 1, j + 1)] - [f(i - 1, j - 1) + f(i, j - 1) + f(i + 1, j - 1)]|;

[0066] Then:

[0067] P(i, j) = max[G x , G y or P(i, j) = G x + G y

[0068] In the formula:

[0069] i represents the abscissa of the pixel point;

[0070] j represents the ordinate of the pixel point;

[0071] f() represents the digital image;

[0072] G x represents the horizontal edge intensity;

[0073] G y represents the horizontal edge intensity;

[0074] P() represents the pixel point edge intensity function.

[0075] For the finally output edge image, it is obtained according to G = max(G x , G y ). All pixel points whose gray value is greater than or equal to the threshold are considered as edge points, that is, an appropriate threshold T is selected. If G ≥ T, then the corresponding pixel point is an edge point.

[0076] In step seven, the circular trajectory is extracted from the set of image edge points extracted in step six through the RHT detection algorithm as the base circle.

[0077] The specific process in step seven is as follows:

[0078] Since the center coordinates of the base circle obtained by fusion are located at (a, b), and assuming the radius of the base circle is R, the standard equation of the base circle trajectory is:

[0079] (x - a) 2 +(y - b) 2 =R 2

[0080] Randomly select three points (x1, y1), (x2, y2), (x3, y3) on the base circle.

[0081] Then there are:

[0082]

[0083] Solving the above equations gives: the center coordinates (a, b) and the radius R, which is the point (a, b, R) in the parameter space. The RHT detection algorithm is to continuously sample three points in the image space, map them into a point in the parameter space, and finally extract the peak value of the parameter space accumulator to realize the base circle trajectory detection. The calculation process is as follows:

[0084] Map three non - collinear points in the image coordinate space to a point in the three - dimensional parameter space, forming a "many - to - one" correspondence. First, select three points on the circle in the coordinate space, use the properties of the circumscribed circle to solve the parameter values, record the parameter values in the parameter space, and mark the positions of these points in the edge point set; then determine the valid parameter points according to the voting mechanism in the parameter space, and extract the points that meet a certain threshold as the required curve parameters.

[0085] Step eight, extract the radius R parameter of the base circle obtained in step seven, perform a linear transformation and logical correspondence between the radius R parameter of the base circle and the actual control physical quantity, and calculate the system load of the large - diameter pipe - following rig in real time.

[0086] According to the system load, decide the working parameters of the large - diameter pipe - following rig, and adjust the overflow thresholds of the rotation and feed of the large - diameter pipe - following rig in real time through the PWM output of the PID adjustment controller to achieve the high - efficiency operation of the system and improve the drilling efficiency of the rig.

[0087] In this embodiment, the radius of the base circle is proportional to the overall load of the rig. According to the size of the base circle, the rotation torque and feed force of the large - diameter pipe - following rig can be decided in real time to improve the operation efficiency of the rig.

[0088] Specifically in step eight, based on the coupling characteristics of the electro - mechanical - hydraulic parameters, measure the structural parameters of the base circle to obtain the system fault signal and load status of the pipe - following rig, obtain the system feed force control variable according to the difference between the actual complex situation and the high - efficiency load, and adjust the rig operation in the high - efficiency interval in real time.

[0089] The specific coupling principle in step eight is as follows:

[0090] The electromechanical-hydraulic coupling model of a three-phase asynchronous motor - hydraulic pump rotor system is as Figure 3 shown. Assume that the rotating shafts of the hydraulic pump and the three-phase asynchronous motor 2 are connected by an elastic coupling, and the connection base of the hydraulic pump and the three-phase asynchronous motor 2 is rigidly connected. After the three-phase asynchronous motor 2 operates, due to the influence of misalignment and eccentricity between the two, the rotor system will vibrate in the horizontal and vertical directions. In addition, torsional vibration (in the δ direction) will occur in the rotating shaft of the three-phase asynchronous motor 2 under the conditions of system startup, braking, and load impact. When torsional vibration occurs in the three-phase asynchronous motor 2, the ω r and θ between the rotating shaft of the hydraulic pump and the rotating shaft of the three-phase asynchronous motor 2 will change.

[0091] Based on the above model, the system dynamic model is established as:

[0092]

[0093] In the formula:

[0094] J p represents the moment of inertia of the hydraulic pump rotor;

[0095] m represents the mass of the hydraulic pump rotor;

[0096] e represents the eccentricity;

[0097] θ represents the angle of the hydraulic pump rotor;

[0098] represents the angular acceleration of the hydraulic pump rotor;

[0099] M e represents the torque of the three-phase asynchronous motor;

[0100] J e represents the moment of inertia of the three-phase asynchronous motor rotor;

[0101] p represents the number of pole pairs of the three-phase asynchronous motor;

[0102] ω r represents the acceleration of the three-phase asynchronous motor;

[0103] p p represents the actual pressure at the pump outlet;

[0104] q represents the pump displacement;

[0105] η p represents the pump efficiency;

[0106] represents the horizontal axis acceleration;

[0107] represents the vertical axis acceleration;

[0108] g represents the acceleration due to gravity.

[0109] Figure 3 In it, M p represents the torque of the hydraulic pump rotor; δ represents the torsional angle of the mechanical rotating shaft.

[0110] As can be seen from the above, the torque M of the three-phase asynchronous motor 2 e combines electromagnetic and mechanical phenomena. The electrical parameters of the three-phase asynchronous motor 2, the misalignment or eccentricity of the mechanical installation, and the pressure of the hydraulic system will be coupled to the three-phase current signal of the three-phase asynchronous motor 2 through the vibration in the horizontal and vertical directions. Therefore, the monitoring of the operating state and fault conditions of the hydraulic system in terms of electricity, mechanics, and hydraulics can be achieved by detecting the phase current on the stator side of the three-phase asynchronous motor 2.

[0111] Step Nine, calculate the distance R between the base circle coordinates obtained in Step Seven and the actual trajectory coordinates at the same moment L , when R L is greater than the normal value, output the fault alarm information of the large-diameter pipe-following rig. Relevant technical personnel perform maintenance diagnosis on the large-diameter pipe-following rig.

Claims

1. A large-diameter pipe drilling rig fault diagnosis and intelligent decision-making system, wherein the large-diameter pipe drilling rig (1) comprises a hydraulic pump (101), the hydraulic pump (101) drives a rotary load (103) through a hydraulic motor (102); the hydraulic pump (101) also drives a feed load (105) through a hydraulic cylinder (104); the characteristics are: The hydraulic pump (101) is also connected to a three-phase asynchronous motor (2), and the three-phase asynchronous motor (2) is connected to a three-phase current detection sensor (4) inside the starter cabinet (3), and the three-phase current detection sensor (4) is used to collect the stator side phase current signal of the three-phase asynchronous motor (2); The three-phase current detection sensor (4) is connected to the input end of the 485 signal conversion module (5) inside the starter cabinet (3), and the 485 signal conversion module (5) is used to convert analog quantities into digital quantities; The output end of the 485 signal conversion module (5) is connected to the input end of the controller (7) inside the flameproof and intrinsically safe control cabinet (6) for communication, and reads the three-phase current signal on the stator side of the three-phase asynchronous motor (2) transmitted by the starter cabinet (3) in real time.

2. The large diameter pipe drilling rig fault diagnosis and intelligent decision-making system according to claim 1, characterized in that: The three-phase current detection sensor (4) comprises three Hall current sensors, and the three Hall current sensors are respectively installed on the three-phase power supply introduction lines of the three-phase asynchronous motor (2).

3. A large diameter pipe drilling rig fault diagnosis and intelligent decision-making method, characterized in that: The method adopts the large-diameter pipe drilling rig fault diagnosis and intelligent decision-making system as described in claim 1 or 2.

4. The fault diagnosis and intelligent decision-making method for a large-diameter pipe drilling rig according to claim 3, characterized in that: The method comprises the following steps: Step 1: a three-phase current detection sensor (4) collects a stator-side phase current signal of a three-phase asynchronous motor (2); Step 2: transmitting the collected stator side phase current signal of the three-phase asynchronous motor (2) to the controller (7) through the 485 signal conversion module (5); Step 3, performing Clark coordinate transformation operation on the stator side phase current signal of the three-phase asynchronous motor (2); Step 4: The stator side phase current i of the three-phase asynchronous motor (2) is a 、i b and i c Orthogonal to the two-phase current i x and i y Perform vector transformation between Step 5: x is the horizontal axis, i y The vertical axis is fused in the plane coordinate system to form a two-dimensional graph and output in the form of an image; Step 6: Use the prewitt operator to perform edge detection on the image output in step 5 to extract the image edge point set; Step 7, extracting a circular trajectory as a base circle from the image edge point set extracted in step 6 through the RHT detection algorithm; Step eight, extracting the radius R parameter of the base circle obtained in step seven, performing linear transformation and logical correspondence between the radius R parameter of the base circle and the actual control physical quantity, and calculating the system load of the large-diameter pipe drilling rig in real time; According to the system load, the working parameters of the large-diameter pipe drilling rig are determined, and the overflow thresholds of the rotation and feeding of the large-diameter pipe drilling rig are adjusted in real time through the PWM output of the PID regulation controller; Step 9: Calculate the distance R between the base circle coordinates obtained in step 7 and the actual trajectory coordinates at the same time L , when R L When it is greater than the normal value, the fault alarm information of the large diameter pipe drilling rig is output.

Images