A coal mine fully mechanized working face OCS optical fiber intelligent communication control method and system

Abstract

The application discloses a kind of coal mine fully mechanized working face OCS optical fiber intelligent communication control method and system, the method includes the following steps: step one: through OCS gateway controller, realize the interconnection of fully mechanized working face equipment, step two: through OCS gateway controller access shearer, scraper, crusher, transfer machine, coal cutting machine signal and working face communication telephone lock, realize equipment state information real-time monitoring and emergency function, step three: through three-dimensional modeling and digital twin technology, the state information of hydraulic support is mapped into digital twin model in real time, step four: fault positioning and coal cutting operation are carried out through digital twin model, step five: the fault diagnosis result is output through visual module, realize accurate maintenance, the system includes: equipment interconnection and data transmission module, equipment state monitoring and emergency stop lock module, three-dimensional modeling and digital twin model integration module, the present application has the characteristics of improving production efficiency and safety.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of intelligent communication control, in particular to a coal mine fully mechanized working face OCS optical fiber intelligent communication control method and system. BACKGROUND

[0002] With the continuous development of coal mining technology and the improvement of coal mine safety production demand, the traditional coal mine equipment management and monitoring mode has been difficult to meet the efficiency, safety and intelligent requirements of modern coal mine production. Especially in the process of fully mechanized working face operation, the complexity of equipment and the harshness of working environment make the state monitoring, fault diagnosis, operation control and personnel safety protection become urgent problems to be solved.

[0003] The traditional coal mine equipment monitoring system mainly relies on manual operation and single equipment monitoring system, and there is a lack of effective interconnection between devices, slow information transmission speed, and high fault troubleshooting and maintenance cost. Due to the difference of communication protocols of each device, the data between devices cannot be effectively shared, resulting in the need for manual diagnosis one by one when troubleshooting the device fault, which seriously affects the production efficiency. In addition, the coal mine working face is often underground, which is restricted by complex terrain and communication environment, and the traditional communication network and monitoring system is difficult to realize stable data transmission and equipment operation. Therefore, it is necessary to design a coal mine fully mechanized working face OCS optical fiber intelligent communication control method and system to improve production efficiency and safety. SUMMARY

[0004] The purpose of the present application is to provide a coal mine fully mechanized working face OCS optical fiber intelligent communication control method and system to solve the problems raised in the background.

[0005] In order to solve the above technical problems, the present application provides the following technical scheme: a coal mine fully mechanized working face OCS optical fiber intelligent communication control method, which comprises the following steps:

[0006] Step 1: realize the interconnection of fully mechanized working face equipment through OCS gateway controller;

[0007] Step 2: realize real-time monitoring of equipment state information and emergency function through OCS gateway controller access to coal mining machine, scraper, crusher, transfer machine, coal cutting machine signal and working face communication telephone lock;

[0008] Step 3: realize real-time mapping of hydraulic support state information to digital twin model through three-dimensional modeling and digital twin technology;

[0009] Step 4: fault positioning and coal cutting operation through digital twin model;

[0010] Step 5: Output the fault diagnosis results through the visualization module to achieve precise repair.

[0011] According to the above technical solution, the step of achieving interconnection and interoperability of fully mechanized mining face equipment through the OCS gateway controller includes:

[0012] Install the OCS gateway controller and fix it in the reserved position of the hydraulic support;

[0013] It can accept multiple signal types, including Wi-Fi, Ethernet, CAN, RS485, audio and fiber optic signals;

[0014] Connect the OCS gateway controller to the fully mechanized mining face equipment via fiber optic composite hose cable;

[0015] Insulation testing was performed after installation.

[0016] According to the above technical solution, the steps of accessing the signals of the coal mining machine, scraper conveyor, crusher, transfer conveyor, and coal cutter, as well as the working face communication telephone interlock via the OCS gateway controller to realize real-time monitoring of equipment status information and emergency functions include:

[0017] The status information of each device, including the coal mining machine, scraper conveyor, crusher, transfer conveyor, and coal cutter, is accessed through the OCS gateway controller.

[0018] Configure the device's communication protocol, and set the baud rate, data frame format, and priority;

[0019] Set a high-priority channel for emergency stop interlocking signals;

[0020] Emergency stop signals are acquired via a hardware interface with a response delay of less than 10 milliseconds.

[0021] Configure working face communication telephone and emergency interlock signal and support emergency stop function.

[0022] According to the above technical solution, the step of mapping the state information of the hydraulic support to the digital twin model in real time through 3D modeling and digital twin technology includes:

[0023] The structure and topography of the mine were collected using laser scanning and topographic surveying to construct a three-dimensional view of the mine.

[0024] Define the normal operating range of the hydraulic support in the model; data outside this range are considered abnormal.

[0025] The outlier range is directly written into the model as a threshold using the Simulink module.

[0026] According to the above technical solution, the step of directly writing the anomaly range as a threshold into the model using Simulink includes:

[0027] Data on the hydraulic supports under normal operating conditions over a period of time is collected. The average, standard deviation, maximum, and minimum values ​​of this data are calculated. A tolerance range is set based on the normal data to define the normal fluctuation range. Data exceeding this range is considered abnormal. When the average hydraulic pressure under normal operating conditions is 200 MPa and the standard deviation is 5 MPa, a tolerance range of ±3 standard deviations is set, defining the abnormal range as below 185 MPa or above 215 MPa. Finally, the abnormal range is directly written into the model as a threshold using MATLAB's Simulink module. The mapping relationship between the status information of each hydraulic support and the model parameters is set in the platform. The hydraulic support pressure data is mapped to the hydraulic cylinder pressure display module, and the support pushing stroke data is mapped to the support's extension and retraction state.

[0028] According to the above technical solution, the steps of fault location and coal cutting operation using a digital twin model include:

[0029] When the status data of the hydraulic support is abnormal, the digital twin model automatically enters the fault simulation analysis process;

[0030] Based on the abnormal data, make a preliminary fault diagnosis and identify potential faulty components, such as hydraulic cylinder leakage, oil circuit blockage, and valve failure.

[0031] The digital twin model is used to simulate each possible faulty component and analyze its performance under the current working condition.

[0032] When a single component simulation cannot explain all anomalies, the system enters a multi-component joint analysis to simulate comprehensive failure scenarios of hydraulic cylinders, oil circuits, and valves.

[0033] The system generates a fault diagnosis report based on the simulation results, indicating the specific faulty components and their mutual influences;

[0034] Through the digital twin model interface, commands can be issued directly on the remote operation platform to control the coal cutter, adjust the depth of the coal cutter, change the coal cutting direction, or select the coal cutting area.

[0035] According to the above technical solution, the step of automatically entering the fault simulation analysis process of the digital twin model when the hydraulic support status data is abnormal includes:

[0036] When the hydraulic support pressure data becomes abnormal, the system first performs a comparative analysis of the hydraulic cylinder leakage simulation and pressure change trend. The system assumes that the hydraulic cylinder has malfunctioned (e.g., damaged seals or internal leakage), and adjusts the leakage coefficient within the hydraulic cylinder accordingly. The simulated pressure value was calculated: ,in: It is the pressure obtained through simulation. It refers to the flow rate in the hydraulic system. It is the leakage coefficient of the hydraulic cylinder. It is the resistance of the oil circuit, and the system will simulate the value. Pressure values ​​of real-time hydraulic supports The system compares the two components. If they match, the fault is located in the hydraulic cylinder; otherwise, the fault comes from the next possible component, and the system continues to simulate the next component.

[0037] According to the above technical solution, the step of the system entering multi-component joint analysis to simulate the comprehensive failure scenarios of hydraulic cylinders, oil circuits, and valves when a single component simulation cannot explain all anomalies includes:

[0038] When a single-component simulation cannot explain all anomalies, the system automatically enters multi-component analysis. The system uses the relationships between components established through a digital twin model to perform joint multi-component simulation: The system assumes multiple components are simultaneously malfunctioning, sequentially adjusting the state parameters of the hydraulic cylinder, oil circuit, and valves, and calculating the degree of matching between the simulated values ​​and the abnormal data of the hydraulic support. Assuming simultaneous faults in the hydraulic cylinder and oil circuit, the system applies the following formula to accumulate the abnormal values ​​of each component, simulating the overall system state:

[0039] Total anomalies = ,

[0040] in: Simulated data values ​​for each abnormal component, The corresponding weight coefficient represents the impact of the component's abnormality on the overall failure. n is the number of faulty components. After adjusting the weights and simulation parameters, the system finally selects the combination that is closest to the actual abnormal data and marks it as a collaborative failure source. This process is iterated repeatedly until the best match is found. After completing all failure simulations, the system will generate a final failure diagnosis report, indicating the specific faulty components and their mutual influence.

[0041] According to the above technical solution, the step of outputting fault diagnosis results through a visualization module to achieve precise repair includes:

[0042] The digital twin interface displays the working status and fault location of the hydraulic support in real time, with faulty components highlighted.

[0043] Once the fault is confirmed, the system immediately sends an alarm signal and indicates the location of the fault through an alarm light.

[0044] Based on the diagnostic report, the system generates maintenance suggestions and fault history records, gradually improving the accuracy of fault prediction and diagnosis.

[0045] According to the above technical solution, this method is used to implement an OCS fiber optic intelligent communication control system for fully mechanized coal mining faces, the system comprising:

[0046] The equipment interconnection and data transmission module is used to fuse and process the signals of the fully mechanized mining face equipment through the OCS gateway controller, so as to realize the interconnection and data transmission between the equipment;

[0047] The equipment status monitoring and emergency stop interlocking module is used to realize real-time monitoring of various devices through the OCS gateway controller;

[0048] The 3D modeling and digital twin model integration module is used to realize the virtual mapping of equipment and environment in fully mechanized mining face through 3D modeling and digital twin technology, providing real-time status monitoring, fault location and coal cutting operation functions.

[0049] Compared with existing technologies, the beneficial effects achieved by this invention are as follows: This invention achieves device interconnection and interoperability through an OCS gateway controller, integrates multiple communication protocols, and accurately locates fault sources and provides maintenance suggestions by monitoring the working status of each device in real time and using digital twin models for fault diagnosis and simulation analysis. Combined with remote control functions, users can perform coal cutting operations and equipment control through the digital twin platform, improving work efficiency, optimizing coal cutting paths, and ensuring the safety and reliability of equipment operation. This method significantly improves the intelligence and automation level of fully mechanized coal mining faces, effectively reduces fault handling time and maintenance costs, and enhances production safety and efficiency. Attached Figure Description

[0050] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0051] Figure 1 This is a flowchart of the steps of an OCS fiber optic intelligent communication control method for a fully mechanized coal mining face provided in Embodiment 1 of the present invention;

[0052] Figure 2 This is a schematic diagram of the composition of an OCS fiber optic intelligent communication control system module for a fully mechanized coal mining face, provided in Embodiment 2 of the present invention. Detailed Implementation

[0053] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0054] Example 1:

[0055] Figure 1 This is a flowchart of an OCS fiber optic intelligent communication control method for a fully mechanized coal mining face provided in Embodiment 1 of the present invention. This embodiment can be applied to scenarios such as coal mine equipment maintenance and remote automated coal cutting. The method can be executed by an OCS fiber optic intelligent communication control system for a fully mechanized coal mining face provided in this embodiment. Figure 1 As shown, the method specifically includes the following steps:

[0056] Step 1: Achieve interconnection and interoperability of equipment in the fully mechanized mining face through the OCS gateway controller;

[0057] In this embodiment of the invention, based on the actual needs of the fully mechanized mining face, signal fusion processing is achieved through an OCS gateway controller. The OCS gateway controller integrates multiple intrinsically safe power supplies, a switch, an audio processing module, a personnel positioning base station module, a data isolation and forwarding module, and other functions. It is compatible with and can access various signals such as Wi-Fi, Ethernet, CAN, RS485, audio, and fiber optics. The OCS gateway controller is installed in the reserved position of the hydraulic support and fixed with bolts. Before installation, the installation point of the hydraulic support is checked to ensure that it meets the protection requirements, and the surface is cleaned to ensure good contact. During the installation process, the power supply of the electrical system of the support is connected to the gateway controller, and the ground wire is connected to complete the safety grounding. After the installation is completed, the controller is subjected to an insulation test, and then the fiber optic composite hose cable is laid. Starting from the OCS gateway controller, the cable is laid in sequence, connecting the coal mining machine, scraper conveyor, crusher, transfer conveyor, coal cutter, and hydraulic support of the fully mechanized mining face. During the laying process, the cable path is planned along the equipment of the fully mechanized mining face, and protective pipes are installed to protect the cable.

[0058] For example, the fiber optic composite hose cable is connected to the OCS gateway controller, and the main equipment of the longwall mining face, including hydraulic supports, coal mining machines, scraper conveyors, crushers, and transfer conveyors, is connected through the controller's communication interface. A unified communication protocol is configured between the equipment to ensure that the status information and operation commands of each device can be transmitted and responded to in real time through the fiber optic composite hose cable. At the same time, the working face communication telephone and interlocking data are connected to the gateway controller for unified management and distribution.

[0059] Step 2: Connect the signals of the coal mining machine, scraper conveyor, crusher, transfer conveyor, and coal cutter, as well as the working face communication telephone interlock through the OCS gateway controller to realize real-time monitoring of equipment status information and emergency functions;

[0060] In this embodiment of the invention, based on the equipment interface types and communication protocols of the coal mining machine, scraper conveyor, crusher, transfer conveyor, and coal cutter, the signal output ports of each device are connected to the signal input port of the OCS gateway controller via fiber optic composite hose cables. In the OCS gateway controller, a separate communication address and parameters are configured for each device, including baud rate, data frame format, protocol type, and priority. Furthermore, a high-priority channel is set up for emergency stop interlocking signals with high real-time requirements. The status monitoring parameters of each device are configured and parsed, and real-time data acquisition is achieved through the mapping between the gateway controller and the device signal interfaces.

[0061] For example, the operating voltage and current of the drive motor are collected in real time to assess the equipment's operating load and energy consumption. The temperatures of the drive motor and main reducer are collected to monitor whether the equipment is within a safe operating temperature range. The position of the coal mining machine on the working face trajectory is determined using an encoder or laser rangefinder; the resolution can be adjusted according to working conditions (e.g., 0.1m). The current working mode of the coal mining machine (e.g., cutting, stopped, standby) and its corresponding step length and cutting parameters are collected. The tilt angle and rotation angle of the coal mining machine are collected through inertial navigation sensors to ensure that the equipment attitude is consistent with the preset trajectory. Simultaneously, the working face communication telephone and emergency stop interlock signal are connected to ensure uninterrupted voice communication during equipment operation and to provide equipment stop functionality in emergencies. The emergency stop signal is collected via a hardware interface directly connected to a high-priority interrupt channel, with a response delay of less than 10ms.

[0062] For example, a one-button emergency stop function is configured in the control center to quickly stop equipment operation via a hardware interrupt signal. When the workface communication telephone detects an emergency call signal, it automatically sends an emergency stop command to the OCS gateway controller, achieving a coordinated emergency stop for all equipment. In a real operating environment, the alarm response time and emergency stop interlocking function are tested to ensure that the alarm delay does not exceed the set value (e.g., 200ms) and the emergency stop response meets the design requirements (<10ms).

[0063] Step 3: Map the status information of the hydraulic support into the digital twin model in real time using 3D modeling and digital twin technology;

[0064] In this embodiment of the invention, the status information of the hydraulic support is monitored in real time through the signal of the hydraulic support controller accessed by the OCS gateway controller, such as support number, support pressure, support pushing stroke, support height, support retraction and side protection status, and support posture. Subsequently, structural and topographic data of the mine are collected through surveying and mapping methods such as laser scanning and topographic surveying. The data covers all key structures, support positions, and channel layouts of the mine. The surveying data is then organized and formatted to be suitable for input into 3D modeling tools. Coordinate transformation and data cleaning are performed. Finally, 3D modeling software is used to construct a 3D view of the mine based on the preprocessed surveying data. The model represents the internal structure of the mine, such as channels, branches, key equipment, and supports, and is restored according to the actual scale. In the 3D mine model, the position of each hydraulic support is accurately marked. According to the actual installation angle and orientation information of the support, the corresponding positioning and calibration are performed in the model. When the mine terrain changes greatly or the structure is more complex, the model needs to be further refined by adding information such as shafts, entrances and exits, and ventilation channels to the model.

[0065] For example, based on the usage and material properties of the support, mechanical properties are set in the three-dimensional mine model, including mass, center of gravity, stiffness, damping coefficient, etc. For the hydraulic cylinder and each joint, the extension range of the support rod is set to 0-1000mm, and the tilt angle is set to a range of movement from -10 degrees to +10 degrees. Then, the three-dimensional mine model is imported into the digital twin platform. At this time, the data flow channel from the OCS gateway controller to the twin platform is established using the MQTT protocol to realize the communication connection between the hydraulic support data and the twin model.

[0066] For example, the normal operating range of the hydraulic support's state information is defined in the digital twin model. Specifically, the following method is used: collect working data of the hydraulic support over a period of time under normal operating conditions, calculate the average, standard deviation, maximum, and minimum values ​​of this data, and set a tolerance range based on the normal data to define the normal fluctuation range. Data exceeding this range is considered abnormal. For instance, if the average hydraulic pressure is 200 MPa and the standard deviation is 5 MPa, a tolerance range of ±3 standard deviations is set, defining the abnormal range as below 185 MPa or above 215 MPa. Finally, the abnormal range is directly written into the model as a threshold using MATLAB's Simulink module. The mapping relationship between the state information of each hydraulic support and the model parameters is set in the platform. For example, hydraulic support pressure data is mapped to the hydraulic cylinder pressure display module, and support pushing stroke data is mapped to the support's extension and retraction state. This binds the digital twin model with the real-time state data of the hydraulic support, ensuring that the model state is synchronized with the actual working state in real time.

[0067] Step 4: Use a digital twin model to locate the fault and perform coal cutting operations;

[0068] In this embodiment of the invention, when the real-time status data of the hydraulic support becomes abnormal, the digital twin model automatically enters the fault simulation analysis process to first perform preliminary anomaly identification. Based on the abnormalities in the hydraulic support status data, such as a sudden drop in hydraulic cylinder pressure, flow fluctuations, or support tilt angle deviation, the system makes a preliminary fault judgment. Each anomaly type corresponds to one or more possible fault sources. For example:

[0069] Pressure drop may be caused by hydraulic cylinder leakage, oil circuit blockage, valve failure, etc.

[0070] A decrease in flow rate may be caused by blockage in the oil circuit, abnormal flow valve, or reduced efficiency of the hydraulic pump.

[0071] Displacement deviation may indicate a malfunction in the support telescopic components or a failure in the hydraulic cylinder stroke control;

[0072] Initial identification helps the system pinpoint a series of potentially faulty components. Subsequently, the digital twin model simulates each possible faulty component one by one, analyzing its operating status under current conditions. The specific steps are as follows:

[0073] When the hydraulic support pressure data becomes abnormal, the system first performs a comparative analysis of the hydraulic cylinder leakage simulation and pressure change trend. The system assumes that the hydraulic cylinder has malfunctioned (e.g., damaged seals or internal leakage), and adjusts the leakage coefficient within the hydraulic cylinder accordingly. The simulated pressure value was calculated: ,in: It is the pressure obtained through simulation. It refers to the flow rate in the hydraulic system. It is the leakage coefficient of the hydraulic cylinder. It is the resistance of the oil circuit, and the system will simulate the value. Pressure values ​​of real-time hydraulic supports The two are compared, and if they match, the fault source is located in the hydraulic cylinder; otherwise, the fault comes from the next possible component, and the system continues to simulate the next component.

[0074] For example, when a single-component simulation cannot explain all anomalies, the system automatically enters multi-component analysis. The system uses the relationships between components established through a digital twin model to perform joint multi-component simulation: The system assumes multiple components are simultaneously abnormal, sequentially adjusting the state parameters of components such as hydraulic cylinders, oil circuits, and valves, and calculating the degree of matching between the simulated values ​​and the abnormal data of the hydraulic support. Assuming simultaneous faults in the hydraulic cylinders and oil circuits, the system applies the following formula to accumulate the abnormal value of each component, simulating the overall system state:

[0075] Total anomalies = ,

[0076] in: Simulated data values ​​for each abnormal component, The corresponding weight coefficient represents the impact of the component's abnormality on the overall failure. n is the number of faulty components. After adjusting the weights and simulation parameters, the system finally selects the combination that is closest to the actual abnormal data and marks it as a collaborative failure source. This process is iterated repeatedly until the best match is found. After completing all failure simulations, the system will generate a final failure diagnosis report, indicating the specific faulty components and their mutual influence.

[0077] For example, users can also view the real-time operating status of the fully mechanized mining face equipment through a digital twin model interface, including the position of the coal cutter, the status of the hydraulic supports, and the distribution of the coal seam. Users can directly issue commands on the remote operation platform to control the coal cutter, adjust its depth, change its cutting direction, or select a cutting area. The operating commands are transmitted to the control system via the network and then to the underground equipment via fiber optic signals to control the movement of the coal cutter. Simultaneously, the system combines 3D modeling with mine topographic data, using path optimization algorithms to plan the optimal cutting path for the coal cutter. Based on coal seam hardness, support location, and working environment, it dynamically adjusts the cutting depth and path to maximize operational efficiency and energy utilization.

[0078] Step 5: Output fault diagnosis results through the visualization module to achieve precise repair;

[0079] In this embodiment of the invention, the system displays the working status and fault location of the hydraulic support in real time through a digital twin interface. The faulty component is highlighted in the visualization model, and the changes in fault parameters (such as changes in pressure and flow rate) are also displayed. The faulty location is displayed in red or other conspicuous markers in the 3D mine view. Through color and graphic markings, maintenance personnel can determine the exact location of the faulty component at a glance and check its fault type. Once the fault is confirmed, the system immediately sends an alarm signal, including multiple prompts such as displaying alarm notifications on the control panel and using audible and visual alarm devices, so that on-duty personnel can be informed of the fault occurrence immediately. Simultaneously, each hydraulic support is equipped with a fault alarm light, and the system controls the alarm light of the faulty support to illuminate via commands, instructing maintenance personnel to quickly locate the fault.

[0080] For example, based on the diagnostic report, the system generates maintenance suggestions, such as which seals need to be replaced and a list of parts to be inspected. The results of each fault diagnosis are automatically recorded and stored in the fault history database. Subsequent fault analyses can refer to this historical record to optimize the system's digital twin model and gradually improve the accuracy of fault prediction and diagnosis.

[0081] Example 2:

[0082] Embodiment 2 of the present invention provides an OCS fiber optic intelligent communication control system for fully mechanized coal mining faces.Figure 2 This is a schematic diagram of the module composition of an OCS fiber optic intelligent communication control system for a fully mechanized coal mining face provided in Embodiment 2 of the present invention, as shown below. Figure 2 As shown, the system includes:

[0083] The equipment interconnection and data transmission module is used to fuse and process the signals of the fully mechanized mining face equipment through the OCS gateway controller, so as to realize the interconnection and data transmission between the equipment;

[0084] The equipment status monitoring and emergency stop interlocking module is used to realize real-time monitoring of various devices through the OCS gateway controller;

[0085] The 3D modeling and digital twin model integration module is used to realize the virtual mapping of equipment and environment in fully mechanized mining face through 3D modeling and digital twin technology, providing functions such as real-time status monitoring, fault location and coal cutting operation;

[0086] In some embodiments of the present invention, the device interconnection and data transmission module includes:

[0087] The OCS gateway controller functional integration module integrates multiple intrinsically safe power supplies, switches, audio processing modules, personnel positioning base station modules, and data isolation and forwarding modules. This functional integration supports multiple devices and communication protocols simultaneously, including Wi-Fi, Ethernet, CAN, RS485, audio, and fiber optic.

[0088] The equipment connection and signal transmission module is used to connect the OCS gateway controller to the main equipment such as hydraulic supports, coal mining machines, scraper conveyors, crushers, transfer conveyors, and coal cutters in the fully mechanized mining face through fiber optic composite hose cables.

[0089] The security access and protection module ensures that the hydraulic support mounting points meet protection requirements and undergo insulation testing during the installation of the OCS gateway controller. When connecting the device power supply, grounding and electrical system connections must be performed simultaneously to ensure stable system operation. Furthermore, cable routing should be planned to avoid external interference, and protective conduits should be installed to protect the cables, ensuring the long-term stability and safety of the cable system.

[0090] In some embodiments of the present invention, the equipment status monitoring and emergency stop interlocking module includes:

[0091] The real-time equipment status data acquisition module is used to connect to the signal ports of each device through the OCS gateway controller and collect the operating parameters of each device in real time.

[0092] The emergency stop interlock signal transmission and processing module ensures that the equipment can be shut down quickly in emergency situations. It connects the emergency stop signal to the high-priority interrupt channel of the OCS gateway controller via a hardware interface, ensuring an emergency stop response time of less than 10 milliseconds. Simultaneously, an emergency stop command can be quickly sent via the emergency call signal from the workface communication telephone, enabling coordinated shutdown of all equipment and improving workface safety.

[0093] The one-click emergency stop module is used to configure a one-click emergency stop button in the control center. When an emergency call signal is detected, the system will automatically send an emergency stop command to the OCS gateway controller to immediately stop the operation of all connected devices.

[0094] In some embodiments of the present invention, the 3D modeling and digital twin model integration module includes:

[0095] The 3D modeling and digital twin model building module is used to acquire structural and topographic data of the mine through laser scanning and topographic surveying technologies, and to build a 3D model of the mine. By mapping the real-time status data of hydraulic supports (such as pressure, stroke, attitude, etc.), a digital twin model is created to ensure that the virtual mapping of the mine equipment is consistent with the actual operating status.

[0096] The fault location and simulation analysis module is used to automatically perform fault simulation analysis based on real-time collected data when the condition of the hydraulic support is abnormal.

[0097] The remote control and coal cutting operation module allows users to view the status of the fully mechanized mining face equipment and issue commands in real time through a digital twin model.

[0098] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0099] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for OCS fiber optic intelligent communication control in a fully mechanized coal mining face, characterized in that: The method includes the following steps: Step 1: Achieve interconnection and interoperability of equipment in the fully mechanized mining face through the OCS gateway controller; Step 2: Connect the signals of the coal mining machine, scraper conveyor, crusher, transfer conveyor, and coal cutter, as well as the working face communication telephone interlock through the OCS gateway controller to realize real-time monitoring of equipment status information and emergency functions; Step 3: Map the status information of the hydraulic support into the digital twin model in real time using 3D modeling and digital twin technology; Step 4: When the hydraulic support status data is abnormal, the digital twin model automatically enters the fault simulation analysis process; based on the abnormal data, a preliminary fault judgment is made to identify potential faulty components, including hydraulic cylinder leakage, oil circuit blockage, and valve failure. The system uses a digital twin model to simulate each possible faulty component and analyzes its performance under the current working condition. When the simulation of a single component cannot explain all anomalies, the system enters a multi-component joint analysis to simulate the comprehensive fault conditions of hydraulic cylinders, oil circuits, and valves. The system generates a fault diagnosis report based on the simulation results, indicating the specific faulty components and their mutual influences; Through the digital twin model interface, commands can be issued directly on the remote operation platform to control the coal cutter, adjust the depth of the coal cutter, change the coal cutting direction, or select the coal cutting area. Step 5: Output the fault diagnosis results through the visualization module to achieve precise repair.

2. The OCS fiber optic intelligent communication control method for fully mechanized coal mining faces according to claim 1, characterized in that: The steps for achieving interconnection and interoperability of fully mechanized mining face equipment through the OCS gateway controller include: Install the OCS gateway controller and fix it in the reserved position of the hydraulic support; It can accept multiple signal types, including Wi-Fi, Ethernet, CAN, RS485, audio and fiber optic signals; Connect the OCS gateway controller to the fully mechanized mining face equipment via fiber optic composite hose cable; Insulation testing was performed after installation.

3. The OCS fiber optic intelligent communication control method for fully mechanized coal mining faces according to claim 1, characterized in that: The steps for accessing signals from the coal mining machine, scraper conveyor, crusher, transfer conveyor, and coal cutter, as well as the working face communication telephone interlock via the OCS gateway controller to achieve real-time monitoring of equipment status information and emergency functions include: The status information of each device, including coal mining machine, scraper conveyor, crusher, transfer conveyor, and coal cutter, is accessed through the OCS gateway controller. Configure the device's communication protocol, and set the baud rate, data frame format, and priority; Set a high-priority channel for emergency stop interlocking signals; Emergency stop signals are acquired via a hardware interface with a response delay of less than 10 milliseconds. Configure working face communication telephone and emergency lockout signal and support emergency stop function.

4. The OCS fiber optic intelligent communication control method for fully mechanized coal mining faces according to claim 1, characterized in that: The step of mapping the state information of the hydraulic support into the digital twin model in real time using 3D modeling and digital twin technology includes: The structure and topography of the mine were collected using laser scanning and topographic surveying methods to construct a three-dimensional view of the mine. Define the normal operating range of the hydraulic support in the model; data outside the range are considered abnormal. The Simulink module is used to directly write the outlier range as a threshold into the model.

5. The OCS fiber optic intelligent communication control method for fully mechanized coal mining faces according to claim 4, characterized in that: The step of directly writing the anomaly range as a threshold into the model using Simulink includes: Data on the hydraulic supports under normal operating conditions over a period of time is collected. The average, standard deviation, maximum, and minimum values ​​of this data are calculated. A tolerance range is set based on the normal data to define the normal fluctuation range. Data exceeding this range is considered abnormal. When the average hydraulic pressure under normal operating conditions is 200 MPa and the standard deviation is 5 MPa, a tolerance range of ±3 standard deviations is set, defining the abnormal range as below 185 MPa or above 215 MPa. Finally, the abnormal range is directly written into the model as a threshold using MATLAB's Simulink module. The mapping relationship between the status information of each hydraulic support and the model parameters is set in the platform. The hydraulic support pressure data is mapped to the hydraulic cylinder pressure display module, and the support pushing stroke data is mapped to the support's extension and retraction state.

6. The OCS fiber optic intelligent communication control method for fully mechanized coal mining faces according to claim 1, characterized in that: The step of automatically entering the fault simulation analysis process of the digital twin model when the hydraulic support status data is abnormal includes: When the hydraulic support pressure data becomes abnormal, the system first performs a comparative analysis of the hydraulic cylinder leakage simulation and pressure change trend. The system assumes that the hydraulic cylinder malfunction includes seal damage or internal leakage, and will adjust the leakage coefficient within the hydraulic cylinder accordingly. The simulated pressure value was calculated: ,in: It is the pressure obtained through simulation. It refers to the flow rate in the hydraulic system. It is the leakage coefficient of the hydraulic cylinder. It is the resistance of the oil circuit, and the system will simulate the value. Pressure values ​​of real-time hydraulic supports The system compares the two components. If they match, the fault is located in the hydraulic cylinder; otherwise, the fault comes from the next possible component, and the system continues to simulate the next component.

7. The OCS fiber optic intelligent communication control method for fully mechanized coal mining faces according to claim 1, characterized in that: When a single component simulation cannot explain all anomalies, the system enters a multi-component joint analysis to simulate comprehensive failure scenarios of hydraulic cylinders, oil circuits, and valves, including: When a single-component simulation cannot explain all anomalies, the system automatically enters multi-component analysis. The system uses the relationships between components established through a digital twin model to perform joint multi-component simulation: The system assumes multiple components are simultaneously malfunctioning, sequentially adjusting the state parameters of the hydraulic cylinder, oil circuit, and valves, and calculating the degree of matching between the simulated values ​​and the abnormal data of the hydraulic support. Assuming simultaneous faults in the hydraulic cylinder and oil circuit, the system applies the following formula to accumulate the abnormal values ​​of each component, simulating the overall system state: Total anomalies = , in: Simulated data values ​​for each abnormal component, The corresponding weight coefficient represents the impact of the component's abnormality on the overall failure. n is the number of faulty components. After adjusting the weights and simulation parameters, the system finally selects the combination that is closest to the actual abnormal data and marks it as a collaborative failure source. This process is iterated repeatedly until the best match is found. After completing all failure simulations, the system will generate a final failure diagnosis report, indicating the specific faulty components and their mutual influence.

8. The OCS fiber optic intelligent communication control method for fully mechanized coal mining faces according to claim 1, characterized in that: The steps for achieving precise repair by outputting fault diagnosis results through a visualization module include: The digital twin interface displays the working status and fault location of the hydraulic support in real time, with faulty components highlighted. Once the fault is confirmed, the system immediately sends an alarm signal and indicates the location of the fault through an alarm light. Based on the diagnostic report, the system generates maintenance suggestions and fault history records, gradually improving the accuracy of fault prediction and diagnosis.

9. A fully mechanized coal mining face OCS fiber optic intelligent communication control system, wherein the system is implemented by the control method described in any one of claims 1 to 8; characterized in that: The system includes: The equipment interconnection and data transmission module is used to fuse and process the signals of the fully mechanized mining face equipment through the OCS gateway controller, so as to realize the interconnection and data transmission between the equipment; The equipment status monitoring and emergency stop interlocking module is used to realize real-time monitoring of various devices through the OCS gateway controller; The 3D modeling and digital twin model integration module is used to realize the virtual mapping of equipment and environment in fully mechanized mining face through 3D modeling and digital twin technology, providing real-time status monitoring, fault location and coal cutting operation functions.

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