A coal flow control system and method for fully mechanized mining working face

Abstract

The present invention discloses a coal flow control system and method for a fully mechanized mining face, which belongs to the field of coal mine fully mechanized mining system integration. S1: Automatically arrange the equipment according to the accessed communication conversion module; S2: Obtain the status data of each device in sequence according to the equipment arrangement order; S3: Set a number of coal flow control branches; S4: Based on the acquired status data, plan and control the equipment in each coal flow control branch, and issue planning control parameters; S5: Control and adjust the operating status of the equipment in each coal flow control branch according to the issued planning control parameters to achieve coal flow control. The present invention centrally arranges and controls the equipment related to the production process, and combines it with an adjustable branch control strategy. In production, the coal flow method is used to start and stop the vehicle, and the equipment status is adjusted according to the planning control parameters, thereby reducing labor and reducing energy consumption, strengthening the linkage between equipment, improving production efficiency, and achieving stable and efficient coal mine production.

Description

Technical Field

[0001] The present invention belongs to the field of coal mine fully-mechanized mining system integration, and in particular relates to a fully-mechanized mining working face coal flow control system and method. Background Art

[0002] The fully mechanized coal mining face is short for a fully mechanized coal mining face and is the main production site for underground coal mine operations. The fully mechanized coal mining face consists of three tunnels within the production area. A nearly horizontal horizontal tunnel is connected to two nearly horizontal longitudinal tunnels at both ends, forming a U-shaped structure. The horizontal section is the production operation area, and the two sides are the control and transportation areas. In the horizontal production operation tunnel, a varying number of hydraulic supports are placed side by side (the number of supports varies depending on the horizontal length of the coal wall) to support the top and bottom of the tunnel, thereby forming an operating space that allows coal mining equipment and miners to move normally and complete their work. The two longitudinal tunnels are the chute equipment tunnel and the transportation tunnel. The chute equipment tunnel is used to house various production-related control equipment, while the transportation tunnel is used to house transportation equipment for transporting coal.

[0003] The main production equipment in the fully mechanized mining face includes coal shearers, scraper conveyors, transfer machines, crushers, and belt conveyors. The production process includes coal breaking, coal loading, and coal transportation. The shearer uses the rotating cutterheads on its left and right rocker arms to cut the coal wall, stripping the coal from the coal wall and completing the coal breaking step. While breaking the coal, the shearer cleans the coal blocks and causes them to fall into the scraper trough of the scraper conveyor below, completing the coal loading step. During the coal transportation step, the scraper conveyor uses its internal scraper chain to pull the coal blocks from the scraper trough below the shearer along a fixed transportation route to the transfer machine feed port. Once inside the transfer machine, the crusher further crushes the coal blocks into small pieces for subsequent transportation. The crushed small pieces of coal are transported to the transfer machine discharge port, further transferred to the belt conveyor, and finally transported outside the fully mechanized mining face area via multiple belts.

[0004] The function of the coal flow control system in a fully mechanized mining face is to transport the coal blocks removed from the coal wall by the shearer outside the fully mechanized mining face. This process is carried out by a combination of equipment: a scraper, a transfer machine, a crusher, and a belt conveyor, in the order of coal flow. Specifically, the scraper head is connected to the transfer machine feed, with a crusher installed between the transfer machine feed and discharge. The transfer machine discharge is connected to the head of the belt conveyor, which is typically composed of multiple belts connected in sequence, depending on the length of the transport route.

[0005] In the current underground coal mine production operations, there are many problems to be solved in the production process of coal crushing and loading:

[0006] First, the production process of breaking and loading coal involves the close coordination of multiple devices. However, the current situation in the coal mining industry is that under the strict requirements of coal mine inherent safety and explosion-proof and explosion-proof, each device is almost a stand-alone control device produced by different manufacturers. The equipment only has a single-point control relationship or a simple logical linkage relationship, and lacks overall system integration.

[0007] Secondly, the tunnels on both sides of the comprehensive mining working face are long and narrow, the equipment is far apart, the equipment and the control end are not in the same location, there is insufficient lighting in the tunnel, and there is no video surveillance coverage in the tunnel. As a result, the control end of each device needs to be assigned a dedicated person to be on duty on site, and manual instructions are conveyed through telephones along the underground line. The on-duty personnel control the equipment according to the command of the ground dispatch center, which greatly consumes manpower.

[0008] Third, the traditional production process usually starts against the flow of coal and stops with the flow of coal. That is, the equipment is started in sequence from the far end of the fully-mechanized mining face and moved inward (starting against the flow of coal), and stopped in sequence from the near end of the fully-mechanized mining face and moved outward (stopping with the flow of coal). The main purpose of this production process is to ensure that coal blocks do not accumulate at the transfer point between the two devices during transportation, causing serious production stoppages. By starting the equipment against the flow of coal, it usually takes several minutes or even more than ten minutes for the equipment to run from the outside to the inside. After the entire line is running, the time required for the coal mining machine to cut the coal wall, the coal blocks to be peeled off, and until they are completely transported out of the fully-mechanized mining face is proportional to the on-site transportation distance. This causes the equipment that has not yet received the first batch of coal blocks to be in an unloaded state for a long time, which greatly wastes electricity resources.

[0009] Fourth, the existing coal flow startup solution can only be used for the first startup after the maintenance team completes maintenance. This means that there is no coal on the transport line and the equipment is unloaded. Furthermore, the startup linkage cannot be changed and can only be executed sequentially from the inside out. It cannot be enabled for coal flow startup at any section of the transport line. This simple logic-based linkage does not support multi-branch coal flow control.

[0010] Fifth, the existing scheme for starting the machine along the coal flow only includes multiple belts in the belt conveyor, and does not include other production equipment in the working tunnel for linkage control.

[0011] Therefore, how to provide an efficient system integration solution to effectively connect various devices in series, provide multi-branch coal flow control, and improve the ratio of production to energy consumption while freeing up manpower is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0012] In response to the above-mentioned deficiencies in the prior art, the present invention provides a coal flow control system and method for a comprehensive mining working face, which realizes multi-branch coal flow control through centralized control of multiple equipment in the production process, reduces labor, saves energy consumption, and improves production efficiency.

[0013] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a coal flow control system for a fully mechanized mining working face, comprising:

[0014] The communication conversion module is installed on the control end of each device in the fully mechanized mining working face and is connected to the data acquisition module and the instruction control module through a switch to exchange data with the main controller of the device;

[0015] The data acquisition module is used to collect the operating parameters and status data of each device through the communication conversion module and transmit them to the control panel;

[0016] The command control module is used to receive the planning control instructions from the strategy analysis module and send them to each device through the communication conversion module to control and adjust the device operation status;

[0017] The control panel is used to obtain the parameters and operating status of each link in the fully mechanized mining face, adjust the execution plan strategy and equipment control parameters, and display them in real time;

[0018] The strategy analysis module is used to obtain and transmit planning control instructions with multiple coal flow control branch strategy solutions based on the transmission data of the control panel through real-time data analysis, and then send them to the instruction control module;

[0019] The data acquisition module, command control module, control panel and strategy analysis module are all arranged in a centralized control box of the fully mechanized mining working face.

[0020] Furthermore, the control panel is provided with a data storage unit, a device arrangement unit, a policy setting unit and a data display unit;

[0021] The data storage unit is used to store data packets pushed by the communication conversion module;

[0022] The device arrangement unit is used to program the accessed communication conversion module according to the stored data content;

[0023] The strategy setting unit is used to set a strategy scheme for multiple downstream coal flow control branches;

[0024] The data display unit is used to provide a human-computer interaction interface to visually display equipment data, communication process information, arrangement relationships, and strategic solutions for multiple downstream coal flow control branches.

[0025] Furthermore, the strategy analysis module includes a data analysis unit, a control strategy unit and a planning control unit;

[0026] The data analysis unit is used to obtain real-time and historical data of the device, and then calculate the calculation data for strategy analysis and transmit it to the control strategy unit;

[0027] The control strategy unit is used to perform program judgment on each device based on the strategy scheme of multiple coal flow control branches provided by the strategy setting unit in the control panel and combined with the calculation data transmitted by the data analysis unit, generate control information and parameter information for equipment adjustment, and transmit it to the planning control unit;

[0028] The planning control unit is used to make an overall plan based on the control information and parameter information to determine whether it complies with the control strategy scheme; at the same time, it sends device linkage information, packages the instructions and parameters to be sent to the device into preset control planning instructions, and sends them to the instruction control module.

[0029] A method for controlling coal flow in a fully mechanized mining face comprises the following steps:

[0030] S1. Arrange equipment: Automatically arrange equipment according to the connected communication conversion module;

[0031] S2. Obtain data: Obtain the status data of each device in sequence according to the device arrangement order;

[0032] S3. Setting control branches: Setting several coal flow control branches in the coal crushing and loading production process;

[0033] S4. Enable control branch: Based on the acquired status data, plan and control the equipment in each coal flow control branch and issue planning control parameters;

[0034] S5. Control and status adjustment: Control and adjust the operating status of the equipment in each coal flow control branch according to the issued planning control parameters to achieve coal flow control.

[0035] Furthermore, the step S1 includes the following sub-steps:

[0036] S101, regularly reading the operating parameters and status data of each device master controller through the data acquisition module;

[0037] S102, setting a quantity counter N, n memories C1-Cn and n priority variables W1-Wn;

[0038] The number counter N is used to count the number of currently connected communication conversion modules, the memories C1 to Cn are used to store network information corresponding to n device controllers, and the priority variables W1 to Wn are used to store the storage network priorities corresponding to n devices, where N < n.

[0039] S103, monitoring whether there is communication data in the real-time area of ​​the data storage unit;

[0040] If yes, proceed to step S104;

[0041] If not, proceed to step S105;

[0042] S104, mark the arrangement flag variable X=1, and go to step S106;

[0043] S105, mark the arrangement flag variable X = 0, sleep for a set time and then return to step S103;

[0044] S106, obtaining the current batch of data packets in the real-time zone, and calculating the number thereof to obtain the number m of communication conversion modules corresponding to the current batch of data packets, where m<n;

[0045] S107, parsing the current batch of data packets, obtaining the network information carried therein, and storing the information in the corresponding memories C1 to Cm in sequence; the network information includes the MAC address, IP address, and network port of the communication conversion module;

[0046] S108, setting a time threshold T of the timer;

[0047] S109, obtaining the peer network information stored in each memory one by one, constructing a ping command and sending it to the peer, and simultaneously starting a timer to count the time, recording the start time as t0;

[0048] When the working time of the timer reaches the time threshold T and the other end does not respond to the ping command, -1 is stored in the corresponding memory, indicating that the current network of the communication conversion module is unstable;

[0049] When the timer's working time does not reach the time threshold T and the other end responds to the ping command, the current time t1 is recorded and t1-t0 is stored in the corresponding memory as the network delay;

[0050] S1010, check the data stored in each memory and determine whether -1 appears;

[0051] If yes, proceed to step S1011;

[0052] If not, proceed to step S1012;

[0053] S1011, the arrangement flag is marked as X=1, and the network delay monitoring is re-performed for the peer end whose value in the memory is -1, and the process returns to step S1010;

[0054] S1012, the arrangement flag variable is marked as X=0, and the process goes to step S1013;

[0055] S1013. Take out the network delays in the memory and sort them. Fill the corresponding peer MAC addresses into the corresponding priority variables W1-Wm in order from low to high according to the network delay. The priority variables W1-Wm are used as the arrangement order of the device main controller.

[0056] Furthermore, step S2 includes the following sub-steps:

[0057] S201, obtaining the device arrangement sequence W1-Wm and the memory C1-Cm;

[0058] S202: Read the MAC addresses of the arrangement sequence W1-Wm in sequence, compare them with the MAC addresses stored in the memories C1-Cm, match the corresponding memories, read the network information in the matching memories, and then construct and send a data collection instruction;

[0059] S203, based on the sent data collection instruction, collect the status data of the corresponding devices one by one and feedback the data packet;

[0060] S204: parse the network information in the feedback data packet, search in W1-Wm, package the data packet together with the retrieved MAC address and device number and send them to the data storage unit to complete the acquisition of device status data.

[0061] Furthermore, the step S203 further includes filtering the collected status data to obtain valid status data, and then feeding back a data packet containing the valid status data;

[0062] In the process of collecting status data of the device, the method of filtering it to obtain valid status data is as follows:

[0063] S203-1. Set the sampling window Q, the timer threshold Y, and the counter quantity threshold F;

[0064] The timer is used to record the timeout period of the collected status data, and the counter is used to record the number of collected status data that meets the standard;

[0065] S203-2, start the timer and counter;

[0066] S203-3. Within the sampling window Q, continuously collect status data until the timer's working time y reaches the set time threshold Y;

[0067] S203-4, determine whether the number of records f in the counter reaches the set threshold F;

[0068] If yes, the collected status data is valid, the collected status data sample is recorded, and the process goes to step S203-5;

[0069] If not, the collected status data is invalid, the timer and counter are reset, and the process returns to step S203-2;

[0070] S203-5. Perform weighted processing on the state data samples collected this time, and use the obtained weighted average data as the effective state data obtained by filtering.

[0071] Furthermore, the step S3 is specifically as follows:

[0072] Obtain the equipment arrangement sequence, match the equipment name with the number in the equipment arrangement sequence, and set several coal flow control branches according to the production requirements of the coal crushing and loading production process;

[0073] In each coal flow control branch, the associated equipment, associated relationships and control strategies are determined according to the equipment arrangement sequence; the associated equipment refers to the equipment required for the coal flow control branch, the associated relationships refer to the working sequence between the associated equipment, and the control strategy refers to the planning scheme for starting / stopping each equipment according to the associated relationships.

[0074] Furthermore, the step S4 includes the following sub-steps:

[0075] S401, according to the workflow of each device in the coal flow control branch, based on the collected status data and the working distances L1-Lm between each device, sequentially calculate the working time T1-Tm from the preceding device to the succeeding device in each process;

[0076] S401, setting the start time of the first device in the coal flow workflow to T0;

[0077] S403. Set planning control parameters for each device according to the working time T1~tm:

[0078] After the preceding device starts at Ti-T0, the succeeding device starts to start;

[0079] Among them, i=1~m-1.

[0080] The beneficial effects of the present invention are:

[0081] Under the complex geological conditions of underground coal mines, the production process of fully mechanized mining faces often relies on the experience of on-site personnel. Compared with existing production processes and technical solutions, the present invention discloses a fully mechanized mining face coal flow control system. By centrally arranging and controlling equipment related to the production process and combining it with an adjustable branch control strategy, it adopts a coal flow-based start and stop method during production, and adjusts equipment status according to planned control parameters. This reduces labor and energy consumption, strengthens the linkage between equipment, improves production efficiency, and achieves stable and efficient coal mine production. Specific advantages include:

[0082] (1) In view of the current situation of the underground coal mining industry, due to the strict requirements of coal mine intrinsic safety and explosion isolation and explosion prevention, the underground production environment of the coal mining industry does not have overall system integration. The present invention uses a communication conversion module to uniformly convert the hardware and protocol of the main controller of a specific device, and connects to the main system through a data acquisition module and an instruction control module. The main system realizes the linkage control of multiple devices, strengthens the linkage between devices, and improves production efficiency.

[0083] (2) The tunnels on both sides of the fully mechanized mining face are long and narrow, the equipment is far apart, the equipment and the control terminal are not in the same location, there is insufficient lighting in the tunnel, and there is no video surveillance coverage in the tunnel. Manual instructions are usually communicated using telephones along the line, which is very labor-intensive. The present invention connects the main controllers of each device to the main system, and completes centralized control through processes such as data analysis, control strategy, and strategy planning, realizing an efficient scheduling process and achieving the goal of unmanned or low-manpower mining.

[0084] (3) The traditional production process is to start the machine against the coal flow and stop it with the coal flow. In medium and large coal mines, the long coal transportation lines cause many subsequent equipment to run idle, which greatly wastes power resources. The present invention uses data collection and data analysis to start the equipment before the next equipment arrives, thereby minimizing energy consumption and achieving the production goal of green mining.

[0085] (4) In the existing coal flow start-up scheme, it can usually only be used on site when the maintenance team completes the maintenance, which has great limitations. The present invention proposes a multi-branch strategy setting, which can set the control strategy according to the on-site situation. The system performs strategy planning based on data analysis and the set strategy, and issues control parameters to achieve multi-branch coal flow control, which solves the limitations of the existing scheme.

[0086] (5) The existing coal flow starting scheme only includes the multiple belts in the conveyor belt, and does not include other production equipment in the working roadway for linkage control. The present invention combines other equipment and belts in the working roadway to achieve coal flow control of the entire fully mechanized mining face. BRIEF DESCRIPTION OF THE DRAWINGS

[0087] Figure 1 This is a structural block diagram of the coal flow control system for the fully mechanized mining working face provided by the present invention.

[0088] Figure 2 This is a flow chart of the coal flow control method for the fully mechanized mining working face provided by the present invention. DETAILED DESCRIPTION

[0089] The specific embodiments of the present invention are described below to facilitate understanding of the present invention by those skilled in the art. However, it should be clear that the present invention is not limited to the scope of the specific embodiments. For those skilled in the art, as long as various changes are within the spirit and scope of the present invention as defined and determined by the appended claims, these changes are obvious, and all inventions and creations utilizing the concepts of the present invention are protected.

[0090] The embodiment of the present invention provides a coal flow control system for a fully mechanized mining face, such as Figure 1 Shown, including:

[0091] The communication conversion module is installed on the control end of each device in the fully mechanized mining working face and is connected to the data acquisition module and the instruction control module through a switch to exchange data with the main controller of the device;

[0092] The data acquisition module is used to collect the operating parameters and status data of each device through the communication conversion module and transmit them to the control panel;

[0093] The command control module is used to receive the planning control instructions from the strategy analysis module and send them to each device through the communication conversion module to control and adjust the device operation status;

[0094] The control panel is used to obtain the parameters and operating status of each link in the fully mechanized mining face, adjust the execution plan strategy and equipment control parameters, and display them in real time;

[0095] The strategy analysis module is used to obtain and transmit planning control instructions with multiple coal flow control branch strategy solutions based on the transmission data of the control panel through real-time data analysis, and then send them to the instruction control module;

[0096] Among them, the data acquisition module, command control module, control panel and strategy analysis module are all set in the centralized control box of the comprehensive mining working face.

[0097] In this embodiment, the installation and deployment of the communication conversion modules strictly follow the anti-interference design specifications of the industrial automation system, and all communication conversion modules are placed on the control end of the equipment or in close proximity to the control end. The purpose of this layout arrangement is to shorten the length of the data acquisition line as much as possible. By reducing the length of the line, not only can the speed of signal transmission be accelerated, but the risk of data loss caused by long-distance transmission can also be effectively reduced. In addition, the production environment in various places underground in the coal mine is in a strong electronic interference environment. As the coal mining process progresses, the interference environment is constantly changing. Such a design also helps to avoid the impact of external electromagnetic interference on signal quality. External interference may cause errors or distortion in data transmission, affecting the stability and reliability of the entire system. Therefore, installing the communication conversion module close to the data source is one of the key measures to ensure the efficient and reliable operation of the system.

[0098] In this embodiment, the back-end of the communication conversion module is connected to a specific production device, and the type, installation structure, and number of mounted sub-devices of the production equipment will change according to the on-site conditions. Therefore, the connection method is usually only connected to the main controller (control end) of the production equipment. At the software level, this system is abstracted as a built-in upper computer program of the communication conversion module and a built-in lower computer program of the device control end for data exchange.

[0099] In one example of this embodiment, the equipment in the fully mechanized mining face includes a coal mining machine, a scraper conveyor, a transfer machine, a crusher and a belt conveyor; Figure 1 In the control system, communication conversion modules M11, M12, M13, M14 and M15 are respectively provided on the coal mining machine control end, the scraper conveyor control end, the transfer machine control end, the crusher control end and the belt conveyor control end.

[0100] Specifically, the communication conversion module M11 is directly connected to the shearer's control terminal, enabling data exchange via a pre-set communication protocol. It is primarily responsible for collecting data from six key components, crucial for monitoring and optimizing the shearer's operating status. These components are the shearer's main oil pump motor, the left and right cutting motors, the left and right traction motors, and the shearer's main controller. Motor data includes current, voltage, and temperature, while main controller data includes operating direction, travel speed, and shearer actions.

[0101] The communication conversion module M12 is connected to the control terminal of the scraper conveyor and implements data exchange by following a preset communication protocol. It is primarily responsible for collecting data from three key components: the status of the tail parallel motor, the nose parallel motor, and the nose vertical motor, including current, voltage, temperature, and scraper chain speed. The scraper conveyor has two directions: parallel and vertical. The nose of the conveyor is divided into a transfer point and connected to the transfer machine.

[0102] The communication conversion module M13 is connected to the transfer machine's control terminal, enabling data exchange based on a pre-set communication protocol. It is primarily responsible for collecting data on the transfer machine's motor status, including current, voltage, temperature, and speed. The transfer machine is located at the intersection of the working and equipment lanes. The entire machine is installed at the head of the equipment lane and is primarily used for transport and transshipment. Due to the distance between its feed and discharge ports, the crusher is typically installed between them.

[0103] The communication conversion module M14 is connected to the crusher's control terminal, enabling data exchange based on a pre-set communication protocol. It is primarily responsible for collecting the crusher's power frequency switch status and current data. Located inside the transfer machine, between the feed and discharge ports, this device crushes large coal lumps after transfer into smaller pieces for easier transportation.

[0104] The communication conversion module M15 is connected to the control terminal of the belt conveyor and implements data exchange based on a pre-set communication protocol. It is primarily responsible for collecting information such as the power frequency on / off status, current data, and conveyor speed of each section of the crusher belt. This belt conveyor typically consists of one or more belts, the number of which is determined by the underground transportation site. It is used to transport coal blocks through complex terrain until they are transported away from the fully mechanized mining face.

[0105] In this embodiment, the communication conversion module is related to the type and quantity of on-site equipment. The five communication conversion modules M11-M15 respectively exchange data with the equipment main control end and provide a unified communication interface, which is connected to the dedicated local area network of the comprehensive mining working face through Ethernet twisted pair or optical fiber, and finally connected to the data acquisition module M2 and command control module M3 of this system.

[0106] In this embodiment, Figure 1 In the process, the data acquisition module M2 is connected to the communication conversion modules M11-M15 on the field equipment, and data acquisition is achieved through a unified communication interface. A scheduled task is used for data polling to obtain the status data of each device, record the communication process information, and package each batch of data, and then actively push it to the control panel M4.

[0107] In this embodiment, Figure 1In the example, the command control module M3 is connected to the communication conversion modules M11-M15 on the field equipment and to the strategy analysis module M5. The command control module M3 receives the planning control parameters sent by the strategy analysis module M4 and, based on the current communication status, issues planning control commands to the communication conversion modules M11-M15. Specifically, the command control module M3 receives the coordinated start plan and sequentially executes parking actions for the communication conversion modules specified by the strategy; receives the planning control parameters and adjusts the device-related parameters corresponding to the communication conversion modules specified by the strategy; and receives the coordinated stop plan and sequentially executes parking actions for the communication conversion modules specified by the strategy.

[0108] In this embodiment, Figure 1 In the figure, the control panel M4 is connected to the data acquisition module M2 and the strategy analysis module M5, and the data flow order is M2-M4-M5; the control panel M4 is composed of multiple sub-modules, including a data storage unit M41, a device orchestration unit M42, a strategy setting unit M43 and a data display unit M44.

[0109] The data storage unit M41 is used to store the data packets pushed by the communication conversion module in a specific format;

[0110] The device arrangement unit M42 is used to program the accessed communication conversion module according to the stored data content and the specific addressing logic;

[0111] The strategy setting unit M43 is used to set the strategy scheme of multiple downstream coal flow control branches;

[0112] The data display unit M44 is used to provide a human-computer interaction interface to visualize equipment data, communication process information, arrangement relationships, and strategy solutions for multiple coal flow control branches.

[0113] In one example of this embodiment, the data display unit M44 may be a hardware device such as a liquid crystal display screen, a touch screen, etc.

[0114] In this embodiment, in addition to visually displaying data, arranging equipment, and setting multi-branch control strategy solutions, the control panel M44 can also be used for remote control of stand-alone equipment. Operators operate through the human-computer interaction interface provided by the data display unit M44. The data display unit M44 packages the operating instructions in stand-alone mode and directly skips the data analysis unit M51 and the control strategy unit M52 to the planning control unit M53. After receiving the stand-alone control instructions, the planning control unit M53 immediately delegates the control parameters to the instruction control unit M3 with the highest priority strategy, and promptly controls and sets parameters for the coal mining machine, scraper conveyor, transfer machine, crusher, and belt conveyor. Stand-alone control instructions include equipment start-up and shutdown, and parameter settings for some equipment. All parameter settings need to be entered into the system in advance and stored by the data storage unit M41.

[0115] In this embodiment, the operating interface of the control panel M4 is composed of a series of operating buttons and indicator lights. The number of devices is identified by the device arrangement module M42, and the operating buttons and indicator lights are dynamically generated. In the example operation, the operator can enable and disable the linkage operation of this branch control by pressing the "Policy Enable" and "Policy Shield" buttons; start or stop the devices involved in this branch control by pressing the "Linkage Start" and "Linkage Stop" buttons; and operate the devices individually by pressing the "Single Machine Control" button. When the communication status of a single communication conversion module is normal, the corresponding green light is always on, and when the communication status is in a fault state, the red light is always on, and when the communication is unstable, the yellow light flashes.

[0116] In this embodiment, Figure 1 In the example, the strategy analysis module M5 is connected to the control panel M4 and the instruction control module M3, and the data flow is M4-M5-M3. The strategy analysis module M5 is composed of multiple submodules, including a data analysis unit M51, a control strategy unit M52, and a planning control unit M53.

[0117] The data analysis unit M51 is used to obtain real-time and historical data of the equipment, and calculate the calculation data for strategy analysis through data filtering, data sampling, statistical analysis and other methods, and transmit it to the control strategy unit;

[0118] The control strategy unit M52 is used to perform program judgment on each device based on the strategy scheme of multiple downstream coal flow control branches provided by the strategy setting unit in the control panel and the calculated data transmitted by the data analysis unit, generate control information and parameter information for equipment adjustment, and transmit it to the planning control unit;

[0119] The planning control unit M53 is used to make an overall plan based on the control information and parameter information to determine whether it complies with the strategy plan; at the same time, it sends the equipment linkage information, packages the instructions and parameters to be sent to the device into preset control planning instructions, and sends them to the instruction control module.

[0120] In an embodiment of the present invention, based on the above-mentioned structure of the coal flow control system for a fully mechanized mining face, the present invention also provides a method for working along the coal flow of a fully mechanized mining face, such as Figure 2 As shown, the following steps are included:

[0121] S1. Arrange equipment: Automatically arrange equipment according to the connected communication conversion module;

[0122] S2. Obtain data: Obtain the status data of each device in sequence according to the device arrangement order;

[0123] S3. Setting control branches: Setting several coal flow control branches in the coal crushing and loading production process;

[0124] S4. Enable control branch: Based on the acquired status data, plan and control the equipment in each coal flow control branch and issue planning control parameters;

[0125] S5. Control and status adjustment: Control and adjust the operating status of the equipment in each coal flow control branch according to the issued planning control parameters to achieve coal flow control.

[0126] In step S1 of the embodiment of the present invention, during the automatic arrangement of the equipment, the data adopts the principle of proximity, and the communication conversion module is installed on the control end of each device, and exchanges data with the device main controller, and is connected to the centralized control box via Ethernet twisted pair or optical fiber.

[0127] Based on this, step S1 includes the following sub-steps:

[0128] S101, regularly reading the operating parameters and status data of each device master controller through the data acquisition module;

[0129] S102, setting a quantity counter N, n memories C1-Cn and n priority variables W1-Wn;

[0130] The number counter N is used to count the number of currently connected communication conversion modules to determine how many devices the data in this batch comes from. The memories C1 to Cn are used to store network information corresponding to n device controllers. The priority variables W1 to Wn are used to store the storage network priorities corresponding to n devices, where N < n.

[0131] S103, monitoring whether there is communication data in the real-time area of ​​the data storage unit;

[0132] If yes, proceed to step S104;

[0133] If not, proceed to step S105;

[0134] S104, mark the arrangement flag variable X=1, and go to step S106;

[0135] S105, mark the arrangement flag variable X = 0, sleep for a set time and then return to step S103;

[0136] S106, obtaining the current batch of data packets in the real-time zone, and calculating the number thereof to obtain the number m of communication conversion modules corresponding to the current batch of data packets, where m<n;

[0137] Specifically, the number of the current batch of data packets in the calculation area is calculated to obtain the actual number m, that is, the data obtained by the current batch data acquisition module comes from m communication conversion modules, corresponding to the master terminals of m devices;

[0138] S107, parsing the current batch of data packets, obtaining the network information carried therein, and storing the information in the corresponding memories C1 to Cm in sequence; the network information includes the MAC address, IP address, and network port of the communication conversion module;

[0139] S108, setting a time threshold T of the timer;

[0140] Specifically, a timer is set to obtain network delay data to determine the communication time between the peer device and the system;

[0141] S109, obtaining the peer network information stored in each memory one by one, constructing a ping command and sending it to the peer, and simultaneously starting a timer to count the time, recording the start time as t0;

[0142] When the working time of the timer reaches the time threshold T and the other end does not respond to the ping command, -1 is stored in the corresponding memory, indicating that the current network of the communication conversion module is unstable;

[0143] When the timer's working time does not reach the time threshold T and the other end responds to the ping command, the current time t1 is recorded and t1-t0 is stored in the corresponding memory as the network delay;

[0144] The peer end generally refers to the other computer communicating with the local terminal, and the local terminal-peer end relationship is 1:n. The peer end in this embodiment refers to the communication conversion module;

[0145] S1010, check the data stored in each memory and determine whether -1 appears;

[0146] If yes, proceed to step S1011;

[0147] If not, proceed to step S1012;

[0148] S1011, the arrangement flag is marked as X=1, and the network delay monitoring is re-performed for the peer end whose value in the memory is -1, and the process returns to step S1010;

[0149] Specifically, assuming there are data packets from five communication conversion modules in the real-time zone, this means all five networks are connected. Even when communication is connected, a ping test is still required to obtain network latency. The delay timeout mark -1 is used for retesting. Ultimately, all modules have a certain amount of latency data and are sorted by latency. The length of the network cable and optical fiber determines the size of the communication latency. The smaller the latency, the closer it is to the data acquisition module.

[0150] S1012, the arrangement flag variable is marked as X=0, and the process goes to step S1013;

[0151] S1013. Take out the network delays in the memory and sort them. Fill the corresponding peer MAC addresses into the corresponding priority variables W1-Wm in order from low to high according to the network delay. The priority variables W1-Wm are used as the arrangement order of the device main controller.

[0152] In this embodiment, after the automatic device arrangement is completed through the above process, if a new device is subsequently connected, it will be filled in in an m+1 manner until the system is powered off and restarted to execute the above device arrangement process.

[0153] Step S2 of the embodiment of the present invention includes the following sub-steps:

[0154] S201, obtaining the device arrangement sequence W1-Wm and the memory C1-Cm;

[0155] S202: Read the MAC addresses of the arrangement sequence W1-Wm in sequence, compare them with the MAC addresses stored in the memories C1-Cm, match the corresponding memories, read the network information in the matching memories, and then construct and send a data collection instruction;

[0156] Specifically, read the MAC address of the device numbered 1, that is, read the MAC address stored in W1, compare the read MAC address with the content in the memory, the search range is C1-Cm, match the corresponding memory, and read the network information in the memory, construct the data collection instruction through the network information, and send the data collection instruction.

[0157] After completing the first read-build-send operation, read the MAC address stored in W2 and search it in C1-Cm, and execute the build and send data collection instructions in sequence until the traversal of Wm is completed;

[0158] S203, based on the sent data collection instruction, collect the status data of the corresponding devices one by one and feedback the data packet;

[0159] S204: parse the network information in the feedback data packet, search in W1-Wm, package the data packet together with the retrieved MAC address and device number and send them to the data storage unit to complete the acquisition of device status data.

[0160] In step S203 of the embodiment of the present invention, the method further includes filtering the collected status data to obtain valid status data, and then feeding back a data packet containing the valid status data;

[0161] In the process of collecting status data of the device, the method of filtering it to obtain valid status data is as follows:

[0162] S203-1. Set the sampling window Q, the timer threshold Y, and the counter quantity threshold F;

[0163] The timer is used to record the timeout period of the collected status data, and the counter is used to record the number of collected status data that meets the standard;

[0164] S203-2, start the timer and counter;

[0165] S203-3. Within the sampling window Q, continuously collect status data until the timer's working time y reaches the set time threshold Y;

[0166] S203-4, determine whether the number of records f in the counter reaches the set threshold F;

[0167] If yes, the collected status data is valid, the collected status data sample is recorded, and the process goes to step S203-5;

[0168] If not, the collected status data is invalid, the timer and counter are reset, and the process returns to step S203-2;

[0169] S203-5. Perform weighted processing on the state data samples collected this time, and use the obtained weighted average data as the effective state data obtained by filtering.

[0170] In this embodiment, after completing the data sampling work within the sampling window, the data within the sampling window is weighted averaged. Weighted average is a method for calculating the average value of a set of data, in which different data points have different weights. For the sample data, the weights of the earlier and later time points should be reduced, and the weights of the data in the middle time period should be increased. Because when intercepting the data of a certain period of time, the earlier data and the data before the start time have continuity, the later data and the data after the end time have continuity, and the data in the middle section has more real feedback of the current device, so the lighter ones are taken at the two ends and the heavier ones are taken in the middle. A set of weight sequence {w1, w2, w3, ..., w i}, the value range of w is [0,1]. Its sequence characteristic is that the weight of the front end and the back end is lower than the weight of the middle part. It can be adjusted according to the on-site situation. The formula is as follows:

[0171]

[0172] Where, represents the weight of the i-th state data, Represents the i-th state data.

[0173] In the embodiment of the present invention, step S3 is specifically as follows:

[0174] Obtain the equipment arrangement sequence, match the equipment name with the number in the equipment arrangement sequence, and set several coal flow control branches according to the production requirements of the coal crushing and loading production process;

[0175] In each coal flow control branch, the associated equipment, associated relationships and control strategies are determined according to the equipment arrangement sequence; the associated equipment refers to the equipment required for the coal flow control branch, the associated relationships refer to the working sequence between the associated equipment, and the control strategy refers to the planning scheme for starting / stopping each equipment according to the associated relationships.

[0176] In a specific example of the present invention, the following default linkage start relationship along the coal flow is set, that is, a coal flow control branch set by the system by default:

[0177] The scraper conveyor can only be started after the shearer is started, the transfer machine can only be started after the scraper conveyor is started, the crusher can only be started after the transfer machine is started, and the belt conveyor can only be started after the crusher is started. The belt conveyor usually has one or more belts. The starting order is from the inside to the outside according to the coal flow direction of the fully mechanized mining working face;

[0178] In this embodiment of the present invention, step S4 includes the following sub-steps:

[0179] S401, according to the workflow of each device in the coal flow control branch, based on the collected status data and the working distances L1-Lm between each device, sequentially calculate the working time T1-Tm from the preceding device to the succeeding device in each process;

[0180] S401, setting the start time of the first device in the coal flow workflow to T0;

[0181] S403. Set planning control parameters for each device according to the working time T1~tm:

[0182] After the preceding device starts at Ti-T0, the succeeding device starts to start;

[0183] Among them, i=1~m-1.

[0184] In a specific example of the present invention, for the above-mentioned default setting of the coal flow control branch, the following method is used to plan and control the equipment and issue planning control parameters;

[0185] Obtain equipment data, including the shearer's operating speed V and cutting depth W, as well as static data of the fully mechanized mining face, namely the average height H of the coal wall;

[0186] Calculate the amount of coal produced by the shearer per second, which is the coal wall height × cutting depth × shearer operating speed;

[0187] Obtain the scraper conveyor chain speed V1, and then calculate the time T1 from the coal miner position to the transfer machine feed port; obtain the first distance L1 from the coal miner position to the transfer machine feed port through the coal miner encoder data, and then the time t1 = coal miner distance L1 / scraper chain speed V1;

[0188] Set the equipment start time T0;

[0189] When the scraper conveyor starts at T1-T0, the loader starts;

[0190] Similarly, L2 is the second distance from the feed port of the transfer machine to the crusher, L3 is the third distance from the crusher to the discharge port of the transfer machine, L4 is the distance from the first belt to the second belt of the belt conveyor, and L5 is the distance from the second belt to the third belt of the belt conveyor. Calculate the working time T1 to Tm from the preceding equipment to the following equipment in each process in sequence.

[0191] T1-Tm is calculated based on L1-Lm, and each link starts after Ti-T0 after the previous equipment starts.

[0192] Specific embodiments are used in the present invention to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only used to help understand the method of the present invention and its core ideas. At the same time, for those skilled in the art, according to the ideas of the present invention, there may be changes in the specific implementation methods and application scopes. In summary, the contents of this specification should not be understood as limiting the present invention.

[0193] Those skilled in the art will appreciate that the embodiments described herein are intended to help readers understand the principles of the present invention, and it should be understood that the scope of protection of the present invention is not limited to such specific descriptions and embodiments. Those skilled in the art can make various other specific variations and combinations based on the technical teachings disclosed in the present invention without departing from the essence of the present invention, and such variations and combinations are still within the scope of protection of the present invention.

Claims

1. A method for controlling coal flow in a fully mechanized mining face, characterized in that: The system for realizing the coal flow control method of fully mechanized mining working face includes: The communication conversion module is installed on the control end of each device in the fully mechanized mining working face and is connected to the data acquisition module and the instruction control module through a switch to exchange data with the main controller of the device; The data acquisition module is used to collect the operating parameters and status data of each device through the communication conversion module and transmit them to the control panel; The command control module is used to receive the planning control instructions from the strategy analysis module and send them to each device through the communication conversion module to control and adjust the device operation status; The control panel is used to obtain the parameters and operating status of each link in the fully mechanized mining face, adjust the execution plan strategy and equipment control parameters, and display them in real time; The strategy analysis module is used to obtain and transmit planning control instructions with multiple coal flow control branch strategy solutions based on the transmission data of the control panel through real-time data analysis, and then send them to the instruction control module; The data acquisition module, command control module, control panel and strategy analysis module are all arranged in a centralized control box of the fully mechanized mining face; The control panel is provided with a data storage unit, a device arrangement unit, a policy setting unit and a data display unit; The data storage unit is used to store data packets pushed by the communication conversion module; The device arrangement unit is used to program the accessed communication conversion module according to the stored data content; The strategy setting unit is used to set a strategy scheme for multiple downstream coal flow control branches; The data display unit is used to provide a human-computer interaction interface to visualize equipment data, communication process information, arrangement relationships, and strategy solutions for multiple downstream coal flow control branches; The strategy analysis module includes a data analysis unit, a control strategy unit and a planning control unit; The data analysis unit is used to obtain real-time and historical data of the device, and then calculate the calculation data for strategy analysis and transmit it to the control strategy unit; The control strategy unit is used to perform program judgment on each device based on the strategy scheme of multiple coal flow control branches provided by the strategy setting unit in the control panel and combined with the calculation data transmitted by the data analysis unit, generate control information and parameter information for equipment adjustment, and transmit it to the planning control unit; The planning control unit is used to perform overall planning based on the control information and parameter information to determine whether it complies with the control strategy scheme; at the same time, it issues device linkage information, packages the instructions and parameters to be issued into preset control planning instructions, and sends them to the instruction control module; The method comprises the following steps: S1. Arrange equipment: Automatically arrange equipment according to the connected communication conversion module; S2. Obtain data: Obtain the status data of each device in sequence according to the device arrangement order; S3. Setting control branches: Setting several coal flow control branches in the coal crushing and loading production process; S4. Enable control branch: Based on the acquired status data, plan and control the equipment in each coal flow control branch and issue planning control parameters; S5. Control and status adjustment: Control and adjust the operating status of the equipment in each coal flow control branch according to the issued planning control parameters to achieve coal flow control; The step S2 comprises the following sub-steps: S201, obtaining the device arrangement sequence W1-Wm and the memory C1-Cm; S202: Read the MAC addresses of the arrangement sequence W1-Wm in sequence, compare them with the MAC addresses stored in the memories C1-Cm, match the corresponding memories, read the network information in the matching memories, and then construct and send a data collection instruction; S203, based on the sent data collection instruction, collect the status data of the corresponding devices one by one and feedback the data packet; S204: parse the network information in the feedback data packet, search for it in W1-Wm, and package the data packet together with the retrieved MAC address and device number and send it to the data storage unit to complete the acquisition of device status data; The step S203 further includes filtering the collected status data to obtain valid status data, and then feeding back a data packet containing the valid status data; In the process of collecting status data of the device, the method of filtering it to obtain valid status data is as follows: S203-1. Set the sampling window Q, the timer threshold Y, and the counter quantity threshold F; The timer is used to record the timeout period of the collected status data, and the counter is used to record the number of collected status data that meets the standard; S203-2, start the timer and counter; S203-3. Within the sampling window Q, continuously collect status data until the timer's working time y reaches the set time threshold Y; S203-4, determine whether the number of records f in the counter reaches the set threshold F; If yes, the collected status data is valid, the collected status data sample is recorded, and the process goes to step S203-5; If not, the collected status data is invalid, the timer and counter are reset, and the process returns to step S203-2; S203-5. Perform weighted processing on the state data samples collected this time, and use the obtained weighted average data as the effective state data obtained by filtering.

2. The method for controlling the flow of coal in a fully mechanized mining face according to claim 1, characterized in that: The step S1 includes the following sub-steps: S101, regularly reading the operating parameters and status data of each device master controller through the data acquisition module; S102, setting a quantity counter N, n memories C1-Cn and n priority variables W1-Wn; The number counter N is used to count the number of currently connected communication conversion modules, the memories C1 to Cn are used to store network information corresponding to n device controllers, and the priority variables W1 to Wn are used to store the storage network priorities corresponding to n devices, where N < n. S103, monitoring whether there is communication data in the real-time area of ​​the data storage unit; If yes, proceed to step S104; If not, proceed to step S105; S104, mark the arrangement flag variable X=1, and go to step S106; S105, mark the arrangement flag variable X = 0, sleep for a set time and then return to step S103; S106, obtaining the current batch of data packets in the real-time zone, and calculating the number thereof to obtain the number m of communication conversion modules corresponding to the current batch of data packets, where m<n; S107, parsing the current batch of data packets, obtaining the network information carried therein, and storing the information in the corresponding memories C1 to Cm in sequence; the network information includes the MAC address, IP address, and network port of the communication conversion module; S108, setting a time threshold T of the timer; S109, obtaining the peer network information stored in each memory one by one, constructing a ping command and sending it to the peer, and simultaneously starting a timer to count the time, recording the start time as t0; When the working time of the timer reaches the time threshold T and the other end does not respond to the ping command, -1 is stored in the corresponding memory, indicating that the current network of the communication conversion module is unstable; When the timer's working time does not reach the time threshold T and the other end responds to the ping command, the current time t1 is recorded and t1-t0 is stored in the corresponding memory as the network delay; S1010, check the data stored in each memory to determine whether -1 appears; If yes, proceed to step S1011; If not, proceed to step S1012; S1011, the arrangement flag is marked as X=1, and the network delay monitoring is re-performed for the peer end whose value in the memory is -1, and the process returns to step S1010; S1012, the arrangement flag variable is marked as X=0, and the process goes to step S1013; S1013. Take out the network delays in the memory and sort them. Fill the corresponding peer MAC addresses into the corresponding priority variables W1-Wm in order from low to high according to the network delay. The priority variables W1-Wm are used as the arrangement order of the device main controller.

3. The method for controlling coal flow in a fully mechanized mining face according to claim 1, characterized in that: The step S3 is specifically as follows: Obtain the equipment arrangement sequence, match the equipment name with the number in the equipment arrangement sequence, and set several coal flow control branches according to the production requirements of the coal crushing and loading production process; In each coal flow control branch, the associated equipment, associated relationships and control strategies are determined according to the equipment arrangement sequence; the associated equipment refers to the equipment required for the coal flow control branch, the associated relationships refer to the working sequence between the associated equipment, and the control strategy refers to the planning scheme for starting / stopping each equipment according to the associated relationships.

4. The method for controlling coal flow in a fully mechanized mining face according to claim 1, characterized in that: The step S4 comprises the following sub-steps: S401, according to the workflow of each device in the coal flow control branch, based on the collected status data and the working distances L1-Lm between each device, sequentially calculate the working time T1-Tm from the preceding device to the succeeding device in each process; S401, setting the start time of the first equipment in the coal flow workflow to T0; S403. Set planning control parameters for each device according to the working time T1~tm: After the preceding device starts at Ti-T0, the succeeding device starts to start; Among them, i=1~m-1.

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