Hydraulic support device and electro-hydraulic control system

Abstract

The invention provides a hydraulic support device and an electro-hydraulic control system, and relates to the technical field of hydraulic support control. According to the hydraulic support device and the electro-hydraulic control system, a hydraulic support electro-hydraulic controller is connected with an electromagnetic valve driver through an RS485 communication line and used for outputting an RS485 action signal, and the electromagnetic valve driver receives the RS485 signal and analyzes the RS485 signal into a corresponding electromagnetic valve control signal according to an address; the electromagnetic valve driver is connected with the PLC digital quantity input module through a data transmission line, analyzed electromagnetic valve control signals are transmitted to the PLC digital quantity input module, the PLC digital quantity input module is electrically connected with the PLC, and the PLC is connected with the upper computer and the displayer through communication lines. Simulation testing can be completed through cooperation of all the modules, connection with an actual hydraulic support is not needed, and tedious preparation work and possible potential safety hazards during program optimization testing through connection with the hydraulic support are effectively avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of hydraulic support control, and specifically to a hydraulic support device and an electro-hydraulic control system. Background Art

[0002] The electro-hydraulic control system of hydraulic supports is the core of the fully mechanized coal mining face. In the early stage, manual control was mainly used, with high labor intensity and low efficiency. With the development of technology, systems based on single-chip microcomputers or PLCs have achieved centralized and partial automation control. Sensors are used to monitor the status, and the controller manipulates solenoid valves to complete the actions of the supports. The application of communication technology enables remote monitoring and data transmission. At the same time, redundant design and other measures are adopted to improve reliability. In recent years, it is moving towards the direction of intelligence to improve the automation level and efficiency of coal mining.

[0003] Currently, the existing electro-hydraulic control systems need to connect multiple hydraulic supports, and on the supports, it is necessary to install all the intrinsically safe electromagnetic pilot valves for mines, intrinsically safe pressure sensors for mines, and intrinsically safe inclination sensors for mines in place. It is necessary to connect a pump station to provide a pressure source for the supports. The preparatory work for program testing and verification is too cumbersome, and there are certain safety hazards in connecting hydraulic supports for program optimization testing. Summary of the Invention

[0004] Aiming at the deficiencies of the prior art, the present invention provides a hydraulic support device and an electro-hydraulic control system, which solve the problem that the process of hydraulic support program testing is too cumbersome.

[0005] To achieve the above objectives, the present invention realizes a hydraulic support device and an electro-hydraulic control system through the following technical solutions, including:

[0006] Signal Output and Analysis Module: The electro-hydraulic controller of the hydraulic support is connected to the solenoid valve driver through an RS485 communication line, and is used to output RS485 action signals. The solenoid valve driver receives the RS485 signals and resolves them into corresponding solenoid valve control signals according to the address.

[0007] Signal Acquisition and Upload Module: The solenoid valve driver is connected to the PLC digital input module through a data transmission line, and transmits the resolved solenoid valve control signals to the PLC digital input module. The PLC digital input module is electrically connected to the PLC controller, and the PLC controller is connected to the upper computer and the display through a communication line, and is used to upload the signals collected by the digital input module to the upper computer. The upper computer and the display receive and display the uploaded signals.

[0008] Analog signal output module: The PLC controller is electrically connected to the PLC digital output module. The PLC digital output module is connected to the sensor input end of the support controller through an analog signal transmission line. The PLC digital output module is used to send analog signals, and the sensor input end of the support controller receives the analog signals to simulate the data change of the sensor when the support moves;

[0009] Communication module: The communication module is respectively connected to the electro-hydraulic controller of the hydraulic support, the PLC controller and the upper computer through communication lines, and is used to achieve stable communication among the three, support multiple communication protocols. The communication module adopts a redundant design. When the main communication link fails, it automatically switches to the standby communication link to ensure the continuity of system communication.

[0010] Preferably, when the system upgrades and modifies the program of the electro-hydraulic controller of the support, it is not necessary to connect the actual hydraulic support, and the simulation test can be completed through the cooperation of the above modules, effectively avoiding the cumbersome preparation work and potential safety hazards when connecting the hydraulic support for program optimization testing.

[0011] Preferably, the solenoid valve control signal is not connected to the solenoid valve, but is connected to the PLC digital input module for signal acquisition and uploading. Based on the received signal, the upper computer analyzes the action signal law of the electro-hydraulic controller of the hydraulic support through the built-in data processing algorithm, including information such as the trigger frequency, duration, and address distribution of the signal, providing data support for program optimization.

[0012] Preferably, the PLC controller is built with a data processing unit, which is controlled by the central processing chip inside the controller and can perform preprocessing operations such as filtering, amplifying, and encoding on the collected signals to improve the accuracy and reliability of the signals uploaded to the upper computer.

[0013] Preferably, the upper computer is installed with special data analysis software. The PLC controller transmits the preprocessed signals to the upper computer through the communication module in a digital communication protocol. The data analysis software performs real-time analysis, storage, and report generation on the received signals.

[0014] Preferably, the analog signals sent by the analog signal output module can be adjusted according to preset parameters to simulate the data change of the sensor when the support moves under different working conditions, so as to more comprehensively test the program of the electro-hydraulic controller of the support. The preset parameters are set through the upper computer interface and transmitted to the PLC controller through the communication module. The PLC controller controls the PLC digital output module to output corresponding analog signals.

[0015] Preferably, the PLC controller is provided with a fault diagnosis function module, which, based on preset fault diagnosis rules, monitors in real time the abnormal conditions in the signal acquisition and uploading process and the analog signal output process, including signal loss, abnormal signal fluctuations, module communication interruption, etc. When a fault is detected, an alarm signal is sent to the host computer in a timely manner through the communication line, and the fault information is recorded for subsequent analysis.

[0016] Preferably, the host computer can remotely upgrade and configure the program of the support electro-hydraulic controller, and transmit the upgrade file and configuration parameters to the hydraulic support electro-hydraulic controller through the communication module to achieve convenient program update. During the program upgrade process, a secure and encrypted communication connection is established between the host computer and the hydraulic support electro-hydraulic controller to ensure the stability of the upgrade process and the security of the data.

[0017] The present invention provides a hydraulic support device and an electro-hydraulic control system. It has the following beneficial effects:

[0018] 1. The present invention can complete the simulation test through the cooperation of each module without connecting to the actual hydraulic support, effectively avoiding the cumbersome preparation work and potential safety hazards when connecting the hydraulic support for program optimization testing, and eliminating the safety risks that may be caused by connecting the actual support for program testing from the root.

[0019] 2. The present invention preprocesses the collected signals such as filtering and amplifying through the built-in data processing unit of the PLC controller, combines with the special data analysis software of the host computer to realize real-time signal analysis, storage and report generation. At the same time, the analog signal output module can simulate different working condition data and is equipped with a fault diagnosis function, comprehensively ensuring the accuracy and reliability of the test data, and providing more comprehensive data support for program optimization. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the system flow of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0022] Embodiment:

[0023] As Figure 1 shown, the embodiment of the present invention provides a hydraulic support device and an electro-hydraulic control system, including:

[0024] Signal output and analysis module: Select the hydraulic support electro-hydraulic controller of model , and connect it with the solenoid valve driver of model ZY-DCQFQ01 through RS485 communication line. The electro-hydraulic controller has stable RS485 signal output capability, and the solenoid valve driver accurately receives and analyzes RS485 signals;

[0025] Signal acquisition and upload module: Use shielded twisted pair as the data transmission line to connect the ZY-DCQFQ01 solenoid valve driver and the PLC digital input module of the Siemens controller, electrically connect the digital input module to the controller, and then connect the controller to Advantech's industrial-grade host computer and display through the Ethernet communication line.

[0026] Analog signal output module: Let the controller be electrically connected to the Siemens SM153-1 analog output module, which can output high-precision analog signals. It is connected to the sensor input end of the bracket controller through the analog signal transmission line to simulate the data changes of the sensor when the bracket moves.

[0027] Communication module: The communication module is constructed by using Hirschmann MICEM6240 industrial Ethernet switch and Advantech EKI-1521 serial device networking server, and is connected to the hydraulic support electro-hydraulic controller, controller and Advantech host computer through communication lines. The communication module supports multiple communication protocols and adopts redundant design. The main communication link uses industrial Ethernet switch to realize Ethernet communication, and the backup communication link uses RS485 communication through the serial device networking server. When the main communication link fails, it can automatically switch to the backup communication link to ensure the continuity of system communication.

[0028] When upgrading and modifying the support electro-hydraulic controller program, there is no need to connect the actual hydraulic support. The analog signal is sent through the SM153-1 analog signal output module to simulate the data changes of the sensor when the support moves under different working conditions. For example, the data changes of the displacement sensor of the jack are simulated at different propulsion speeds. The electro-hydraulic controller outputs the corresponding action signal, which is analyzed by ZY-DCQFQ01 and collected by the PLC module of S7-1500 and uploaded to the Advantech host computer to complete the simulation test.

[0029] The solenoid valve control signal output by ZY-DCQFQ01 is not connected to the solenoid valve, but to the PLC module of S7-1500 for signal acquisition and upload. Based on the received signal, Advantech's host computer uses the built-in data processing algorithm to analyze the action signal rules of the hydraulic support electro-hydraulic controller, including the signal trigger frequency, duration, address distribution and other information, to provide data support for program optimization.

[0030] The controller is built with a data processing unit, which is controlled by the central processing chip inside it. When a signal is collected, the data processing unit performs preprocessing operations on the signal, such as filtering, amplifying, and encoding.

[0031] The Advantech host computer is installed with dedicated data analysis software. The controller transmits the preprocessed signal to the host computer through the communication module using a digital communication protocol. The software performs real-time analysis, storage, and generates reports on the received signal, such as generating statistical reports on signals like pressure and displacement.

[0032] The analog signal output by the SM153-1 analog signal output module can be adjusted according to preset parameters. The operator sets the preset parameters through the interface of the Advantech host computer, such as setting the change range and change rate of the analog pressure signal. The set parameters are transmitted to the controller through the communication module, and it controls the SM153-1 to output the corresponding analog signal, so as to more comprehensively test the program of the support electro-hydraulic controller.

[0033] The controller is equipped with a fault diagnosis function module, which, based on preset fault diagnosis rules, monitors the abnormal conditions in the signal acquisition and upload process and the analog signal output process in real time.

[0034] When a fault is detected, the fault diagnosis function module of the controller timely sends an alarm signal to the Advantech host computer through the communication line, and through the sound and light alarm. At the same time, it records the fault information, including the fault occurrence time, fault type, relevant signal data, etc., for subsequent analysis and repair.

[0035] The Advantech host computer can remotely upgrade and configure the program of the support electro-hydraulic controller. It transmits the upgrade file and configuration parameters to the electro-hydraulic controller through the communication module. During the transmission process, the host computer and the electro-hydraulic controller establish a secure encrypted communication connection based on the AES-256 encryption algorithm to ensure the stability of the upgrade process and the security of the data.

[0036] During the program upgrade process, the Advantech host computer monitors the upgrade progress in real time. If the upgrade is interrupted, the host computer automatically attempts to re-transmit the upgrade file and configuration parameters to ensure the smooth completion of the upgrade. After the upgrade is completed, the host computer can perform a function test on the support electro-hydraulic controller to verify the upgrade effect.

[0037] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A hydraulic support device and an electro-hydraulic control system, characterized in that Including: Signal output and parsing module: The electro-hydraulic controller of the hydraulic support is connected to the solenoid valve driver through an RS485 communication line, and is used to output RS485 action signals. The solenoid valve driver receives the RS485 signals and parses them into corresponding solenoid valve control signals according to the addresses. Signal acquisition and upload module: The solenoid valve driver is connected to the PLC digital input module through a data transmission line, and transmits the parsed solenoid valve control signals to the PLC digital input module. The PLC digital input module is electrically connected to the PLC controller, and the PLC controller is connected to the upper computer and the display through a communication line, and is used to upload the signals collected by the digital input module to the upper computer. The upper computer and the display receive and display the uploaded signals. Analog signal output module: The PLC controller is electrically connected to the PLC digital output module. The PLC digital output module is connected to the sensor input end of the support controller through an analog signal transmission line. The PLC digital output module is used to issue analog signals, and the sensor input end of the support controller receives the analog signals to simulate the data change of the sensor when the support moves. Communication module: The communication module is respectively connected to the electro-hydraulic controller of the hydraulic support, the PLC controller and the upper computer through communication lines, and is used to realize stable communication among the three, support multiple communication protocols, and the communication module adopts a redundant design. When the main communication link fails, it automatically switches to the standby communication link to ensure the continuity of system communication.

2. The hydraulic support device and electro-hydraulic control system according to claim 1, characterized in that: When the system upgrades and modifies the program of the electro-hydraulic controller of the support, it is not necessary to connect to the actual hydraulic support, and the simulation test can be completed through the cooperation of the above modules, effectively avoiding the cumbersome preparation work and potential safety hazards when connecting the hydraulic support for program optimization test.

3. The hydraulic support device and electro-hydraulic control system according to claim 1, characterized in that: The solenoid valve control signals are not connected to the solenoid valves, but are connected to the PLC digital input module for signal acquisition and upload. Based on the received signals, the upper computer analyzes the action signal rules of the electro-hydraulic controller of the hydraulic support through the built-in data processing algorithm, including information such as the trigger frequency, duration, and address distribution of the signals, providing data support for program optimization.

4. The hydraulic support device and electro-hydraulic control system according to claim 1, characterized in that: The PLC controller is built with a data processing unit, which is controlled by the central processing chip inside the controller and can perform preprocessing operations such as filtering, amplifying, and encoding on the collected signals to improve the accuracy and reliability of the signals uploaded to the upper computer.

5. The hydraulic support device and electro-hydraulic control system according to claim 1, characterized in that: The upper computer is installed with special data analysis software. The PLC controller transmits the preprocessed signals to the upper computer through the communication module in a digital communication protocol. The data analysis software performs real-time analysis, storage, and report generation on the received signals.

6. The hydraulic support device and electro-hydraulic control system according to claim 1, characterized in that: The analog signals issued by the analog signal output module can be adjusted according to preset parameters to simulate the data change of the sensor when the support moves under different working conditions, so as to more comprehensively test the program of the electro-hydraulic controller of the support. The preset parameters are set through the upper computer interface and transmitted to the PLC controller through the communication module. The PLC controller controls the PLC digital output module to output corresponding analog signals.

7. The hydraulic support device and electro-hydraulic control system according to claim 1, characterized in that: The PLC controller is equipped with a fault diagnosis function module. Based on preset fault diagnosis rules, this module real-time monitors abnormal conditions during the signal acquisition and upload process and the analog signal output process, including signal loss, abnormal signal fluctuations, module communication interruptions, etc. When a fault is detected, an alarm signal is promptly sent to the host computer through the communication line, and at the same time, the fault information is recorded for subsequent analysis.

8. The hydraulic support device and the electro-hydraulic control system according to claim 1, characterized in that: The host computer can remotely upgrade and configure the program of the support electro-hydraulic controller. The upgrade file and configuration parameters are transmitted to the hydraulic support electro-hydraulic controller through the communication module to achieve convenient program updates. During the program upgrade process, a secure encrypted communication connection is established between the host computer and the hydraulic support electro-hydraulic controller to ensure the stability of the upgrade process and the security of the data.

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