Automatic tensioning control method and system for anchor cable in coal mine tunneling roadway

Abstract

The invention relates to the technical field of coal mine underground roadway supporting, in particular to a coal mine tunneling roadway anchor cable automatic tensioning control method and system, and the method comprises the steps: initializing tensioning parameters, a top plate pressure safety threshold value and a pressure deviation allowable range; tensioning pressure original signals, real-time top plate pressure and environment interference data are collected in real time, and the environment interference data comprise humidity and vibration frequency. By collecting environment interference data such as underground humidity and vibration frequency and combining anti-interference filtering processing to correct a tension pressure original signal, the problems of pressure signal attenuation and high-frequency fluctuation caused by an underground complex environment are effectively solved, and it is ensured that tension pressure data are accurate; and according to the comparison result of the real-time top plate pressure and the safety threshold value, the tensioning target pressure and the pressure stabilizing time are adjusted in a self-adaptive mode, and the problem that the anchor cable pre-tightening force is insufficient or too large due to the fact that existing system parameters are fixed is solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of coal mine underground roadway support, in particular to a coal mine tunneling roadway anchor cable automatic tensioning control method and system. BACKGROUND

[0002] The roof stability of the coal mine tunneling roadway is the core prerequisite for ensuring the safety of underground operation. As the mainstream support technology, anchor cable support connects the shallow unstable rock layer and the deep stable rock layer into a whole by applying a preset pre-tightening force to the roof rock layer, thereby inhibiting the roof deformation and preventing collapse. The construction quality of anchor cable support highly depends on the control of the tensioning process, and needs to strictly complete the three key stages of "pressure loading-steady pressure maintaining-mechanical locking" according to the design process. The accuracy (deviation needs to be controlled in a small range) of the tensioning pressure and the stability of the steady pressure stage directly determine whether the anchor cable pre-tightening force matches the roof support requirements. With the intelligent transformation of coal mines, the traditional manual tensioning method (which relies on workers to manually operate oil pumps, read mechanical pressure gauges, and manually record data) is gradually replaced by automatic tensioning systems due to its low efficiency, large error (pressure deviation often exceeds ±5%), poor safety, and other problems. The existing automatic tensioning system controls the oil pump and the main valve through an electric control unit, which can automatically complete pressure regulation and preliminarily solve the drawbacks of manual operation.

[0003] Although the existing coal mine anchor cable automatic tensioning system can realize basic automatic pressure control, it still has the following problems under complex underground conditions: the high humidity in the underground environment can cause the signal transmission of the pressure sensor to attenuate, high dust is easy to adhere to the sensor probe affecting the detection accuracy, and continuous vibration can cause high-frequency fluctuations in the real-time feedback of the tensioning pressure. These disturbances can cause the system to have difficulty maintaining a stable preset pressure during the steady pressure maintaining stage, and pressure overshooting or attenuation often occurs. In addition, the tensioning parameters of the existing system are fixed values preset before construction, and cannot be adjusted in real time according to the dynamic changes of the roadway roof pressure. When the roof pressure suddenly rises or falls due to rock movement, the system still completes tensioning according to the initial parameters, which can cause the anchor cable pre-tightening force to not match the actual roof support requirements: when the pre-tightening force is insufficient, it cannot effectively constrain the roof deformation; when the pre-tightening force is too large, it can easily cause the anchor cable steel strand to break or the roof rock layer to break. At the same time, the existing system does not establish a linkage correction mechanism for "tensioning pressure fluctuation-roof pressure change", and cannot calibrate the pressure deviation in the tensioning process through the real-time data of the roof pressure, which ultimately leads to poor consistency of the support force of anchor cables at different positions and increases the potential risk of local roof collapse in the roadway. SUMMARY

[0004] In view of the deficiencies of the prior art, the present application provides a coal mine tunneling roadway anchor cable automatic tensioning control method and system, which solves the problems of inaccurate tensioning pressure signal due to underground environmental interference, fixed tensioning parameters that cannot adapt to the dynamic roof pressure, and lack of linkage warning when using the prior art.

[0005] To achieve the above object, the present application is implemented by the following technical solutions: a coal mine tunneling roadway anchor cable automatic tensioning control method, comprising:

[0006] initializing tensioning parameters, roof pressure safety threshold and pressure deviation allowable range;

[0007] real-time acquisition of tensioning pressure original signal, real-time roof pressure and environmental interference data, the environmental interference data including humidity and vibration frequency;

[0008] anti-interference filtering processing of the tensioning pressure original signal to obtain the corrected tensioning pressure;

[0009] adaptive adjustment of the tensioning parameters according to the comparison result of the real-time roof pressure and the roof pressure safety threshold, the tensioning parameters including target pressure and pressure stabilization time;

[0010] precise tensioning control according to the adjusted tensioning parameters, so that the corrected tensioning pressure gradually approaches the adjusted target pressure, and when the corrected tensioning pressure reaches the adjusted target pressure, entering the pressure stabilization stage;

[0011] locking the anchor cable after the pressure stabilization stage ends;

[0012] if the real-time roof pressure exceeds the roof pressure safety threshold, or the deviation of the corrected tensioning pressure and the adjusted target pressure continuously exceeds the pressure deviation allowable range, triggering a linkage early warning signal and sending a pause signal to the tunneling equipment.

[0013] Further, the anti-interference filtering processing includes:

[0014] calling Kalman filtering algorithm;

[0015] establishing a filtering model with humidity and vibration frequency as interference coefficients;

[0016] processing the tensioning pressure original signal to obtain the corrected tensioning pressure.

[0017] Further, the adaptive adjustment of the tensioning parameters includes:

[0018] if the real-time roof pressure is greater than the upper limit of the roof pressure safety threshold, increasing the tensioning target pressure and prolonging the pressure stabilization time;

[0019] if the real-time roof pressure is less than the lower limit of the roof pressure safety threshold, decreasing the tensioning target pressure and shortening the pressure stabilization time;

[0020] if the real-time roof pressure is within the roof pressure safety threshold range, keeping the initial tensioning parameters unchanged.

[0021] Further, the precise tension control comprises:

[0022] sending the adjusted parameter instruction to the electric control main valve;

[0023] the electric control main valve controls the oil supply flow of the pneumatic oil pump, so that the corrected tension pressure gradually approaches the adjusted target pressure;

[0024] when the corrected tension pressure reaches the adjusted target pressure, the stable pressure stage is entered;

[0025] in the stable pressure stage, if the deviation of the corrected tension pressure from the adjusted target pressure exceeds the allowable pressure deviation range, the electric control main valve automatically supplements the pressure to the adjusted target pressure.

[0026] Further, the method further comprises:

[0027] after the stable pressure stage ends, the adjusted target pressure, the actual stable pressure time, the roof pressure change curve and the corrected tension pressure curve of the current tension are stored.

[0028] The application also provides a coal mine tunneling roadway anchor cable automatic tension control system, which is applied to the coal mine tunneling roadway anchor cable automatic tension control method.

[0029] the automatic tension execution unit comprises a pneumatic oil pump, an electric control main valve and an anchor cable tensioning tool;

[0030] the real-time monitoring unit comprises a tension pressure sensor, a roof pressure sensor and an environmental interference sensor;

[0031] the data processing unit comprises an anti-interference filtering module and an adaptive parameter adjustment module;

[0032] the linkage control unit;

[0033] The automatic tension execution unit, the real-time monitoring unit, the data processing unit and the linkage control unit realize data interaction through a mine industrial ring network.

[0034] Further, the real-time monitoring unit comprises:

[0035] the tension pressure sensor is used for real-time acquisition of the hydraulic pressure original signal of the tensioning process;

[0036] the roof pressure sensor is used for real-time acquisition of the actual pressure of the roof rock stratum;

[0037] the environmental interference sensor is used for synchronous acquisition of the underground humidity and vibration frequency.

[0038] Further, the data processing unit comprises:

[0039] The anti-interference filtering module is configured to use humidity and vibration frequency data collected by the environmental interference sensor as interference coefficients to perform Kalman filtering on the original signal of the tensioning pressure sensor to obtain a corrected tensioning pressure.

[0040] The adaptive parameter adjustment module is configured to adjust tensioning parameters, including a target pressure and a pressure stabilization time, according to a comparison result of the real-time roof pressure collected by the roof pressure sensor and a preset roof pressure safety threshold.

[0041] Further, the linkage control unit is connected to the data processing unit, the underground sound and light alarm and the tunneling equipment control end through an RS485 bus, and is configured to trigger the underground sound and light alarm to send a warning signal and send a pause signal to the tunneling equipment when the real-time roof pressure exceeds the roof pressure safety threshold or the deviation of the corrected tensioning pressure from the adjusted target pressure continuously exceeds a pressure deviation allowable range.

[0042] Further, all components in the automatic tensioning execution unit, the real-time monitoring unit, the data processing unit and the linkage control unit are designed in a mine explosion-proof type or a mine intrinsic safety type.

[0043] Compared with the prior art, the present application has the following advantages:

[0044] The present application collects environmental interference data such as underground humidity and vibration frequency, corrects the original tensioning pressure signal through anti-interference filtering, effectively solves the problems of pressure signal attenuation and high-frequency fluctuation caused by the complex underground environment, ensures the accuracy of the tensioning pressure data, adaptively adjusts the tensioning target pressure and the pressure stabilization time according to the comparison result of the real-time roof pressure and the safety threshold, avoids the problems of insufficient or excessive anchor cable pretightening force caused by fixed system parameters, triggers a linkage warning and sends a pause signal to the tunneling equipment when the roof pressure exceeds the limit or the tensioning pressure deviation continuously exceeds the allowable range, fills the gap of the lack of linkage correction mechanism in the existing system, stores the tensioning key data to provide support for subsequent optimization, and overall improves the anchor cable tensioning control precision, the roof support adaptability and the underground operation safety, and ensures the stability of the roadway roof. BRIEF DESCRIPTION OF DRAWINGS

[0045] Figure 1 The present application is a method flowchart.

[0046] Figure 2 The present application is a system structure diagram. DETAILED DESCRIPTION

[0047] With reference to the drawings of the embodiments of the present application, the technical solutions in the embodiments of the present application will be described clearly and completely. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments of the present application, all the other embodiments obtained by a person of ordinary skill in the art without creative work are within the protection scope of the present application.

[0048] Please refer to Figure 1 The present application provides a coal mine tunneling roadway anchor cable automatic tensioning control method, comprising:

[0049] initializing tensioning parameters, roof pressure safety threshold and pressure deviation allowable range;

[0050] collecting real-time tensioning pressure original signals, real-time roof pressure and environmental interference data, the environmental interference data including humidity and vibration frequency;

[0051] performing anti-interference filtering processing on the tensioning pressure original signals to obtain corrected tensioning pressure;

[0052] adaptingively adjusting tensioning parameters according to the comparison result of the real-time roof pressure and the roof pressure safety threshold, the tensioning parameters including target pressure and pressure stabilization time;

[0053] performing precise tensioning control according to the adjusted tensioning parameters, so that the corrected tensioning pressure gradually approaches the adjusted target pressure, and when the corrected tensioning pressure reaches the adjusted target pressure, entering the pressure stabilization stage;

[0054] locking the anchor cable after the pressure stabilization stage ends;

[0055] if the real-time roof pressure exceeds the roof pressure safety threshold, or the deviation between the corrected tensioning pressure and the adjusted target pressure continuously exceeds the pressure deviation allowable range, triggering a linkage early warning signal and sending a pause signal to the tunneling equipment.

[0056] Specifically, according to the geological conditions of the tunneling roadway, such as the hardness and thickness of the rock stratum and the support design specification, the target pressure and the pressure stabilization time in the preset tensioning parameters are set, the roof pressure safety threshold is set in combination with the bearing characteristics of the roof rock stratum, and the pressure deviation allowable range is determined with reference to the accuracy requirement of the tensioning equipment. The tensioning pressure sensor is installed on the oil line between the pneumatic oil pump and the anchor cable tensioning machine, and the hydraulic pressure original signal is collected in real time. The roof pressure sensor is arranged at the key support point of the roadway roof to collect the real-time roof pressure. The environmental interference sensor is arranged in the surrounding area of the tensioning equipment to synchronously collect the underground humidity and vibration frequency. The anti-interference filtering processing is performed on the tensioning pressure original signal to eliminate the signal attenuation caused by the humidity and the high-frequency fluctuation caused by the vibration, and the corrected tensioning pressure is obtained. The tensioning parameters are adjusted according to the comparison result of the real-time roof pressure and the safety threshold. If the real-time roof pressure is higher than the upper limit of the safety threshold, the tensioning target pressure is increased to enhance the anchor cable pretightening force, and the pressure stabilization time is prolonged to ensure that the pretightening force is fully transmitted to the deep rock stratum. If the real-time roof pressure is lower than the lower limit of the safety threshold, the tensioning target pressure is reduced to avoid damage to the anchor cable steel strand due to overload, and the pressure stabilization time is shortened to improve the construction efficiency. If the real-time roof pressure is within the safety threshold range, the initial tensioning parameters are maintained to meet the basic support requirement. The tensioning process is controlled according to the adjusted parameters. The oil supply flow of the pneumatic oil pump is adjusted through the electric control main valve to make the corrected tensioning pressure gradually close to the adjusted target pressure. When the corrected tensioning pressure reaches the target pressure, the pressure stabilization stage is entered. After the pressure stabilization stage is ended, the anchor cable locking is completed through the locking mechanism. If the real-time roof pressure exceeds the safety threshold, or the deviation between the corrected tensioning pressure and the target pressure continuously exceeds the allowable range, the linkage early warning signal is triggered immediately, and the pause signal is sent to the tunneling equipment. This can effectively solve the problems of the existing system, such as weak anti-interference ability in the complex underground environment, fixed parameters that cannot adapt to the dynamic pressure change of the roof, and lack of linkage safety mechanism. The tensioning pressure control precision and the adaptability of the roof support are improved, and the potential risk of the roadway roof collapse is reduced.

[0057] In the present embodiment, the anti-interference filtering processing includes:

[0058] The Kalman filtering algorithm is called;

[0059] The humidity and the vibration frequency are taken as the interference coefficients to establish the filtering model;

[0060] The tensioning pressure original signal is processed to obtain the corrected tensioning pressure.

[0061] Specifically, the Kalman filtering algorithm is pre-loaded in the data processing unit. The Kalman filtering algorithm is a mature signal processing technology, which realizes the filtering optimization of the noisy signal through the two core steps of prediction and update, and has been widely used in the field of industrial detection. Therefore, the specific algorithm process and formula will not be described here. After the environmental interference sensor collects the downhole humidity and vibration frequency data, the humidity and vibration frequency are input as interference coefficients into the preset filtering model. The model has established the correlation between the humidity and the pressure sensor signal attenuation vibration frequency and the pressure signal fluctuation amplitude through the pre-experimental analysis. Then, the original signal collected by the tension pressure sensor is input into the filtering model, and the Kalman filtering algorithm is used to filter the interference components in the original signal, eliminate the signal attenuation caused by humidity and the high-frequency noise caused by vibration, and finally output the corrected tension pressure. This processing method can significantly reduce the interference of the complex downhole environment on the tension pressure detection, ensure the accuracy of the tension pressure data, and provide reliable data support for subsequent precise tension control.

[0062] In the present embodiment, the adaptive adjustment of the tension parameters includes:

[0063] If the real-time roof pressure is greater than the upper limit of the roof pressure safety threshold, the tension target pressure is increased and the pressure stabilization time is prolonged;

[0064] If the real-time roof pressure is less than the lower limit of the roof pressure safety threshold, the tension target pressure is reduced and the pressure stabilization time is shortened;

[0065] If the real-time roof pressure is within the range of the roof pressure safety threshold, the initial tension parameters remain unchanged.

[0066] Specifically, in the data processing unit, the upper and lower limits of the roof pressure safety threshold determined based on the roadway rock stratum bearing characteristics and the support design specification are stored, and the pressure adjustment amount ΔP and the time adjustment amount ΔT for parameter adjustment are preset, ΔP is a reasonable pressure increment or decrement set according to the amplitude of the roof pressure exceeding the threshold, and ΔT is a pressure stabilization time increment or decrement matching the pressure adjustment. After receiving the real-time roof pressure data transmitted by the roof pressure sensor in real time, the real-time roof pressure is compared with the safety threshold, and the tensioning parameters are adjusted according to the comparison result in the following manner. When the real-time roof pressure is greater than the upper limit of the roof pressure safety threshold, the adjusted tensioning target pressure is calculated according to the formula P1=P0+ΔP, and the adjusted pressure stabilization time is calculated according to the formula T1=T0+ΔT, wherein P1 is the adjusted target pressure, P0 is the initial target pressure, T1 is the adjusted pressure stabilization time, and T0 is the initial pressure stabilization time; when the real-time roof pressure is less than the lower limit of the roof pressure safety threshold, the adjusted tensioning target pressure is calculated according to the formula P1=P0-ΔP, and the adjusted pressure stabilization time is calculated according to the formula T1=T0-ΔT; when the real-time roof pressure is within the range of the roof pressure safety threshold, the adjusted target pressure P1=P0, and the adjusted pressure stabilization time T1=T0. Through this dynamic adjustment method, the tensioning parameters can adapt to the changes of the roof pressure in real time, avoiding the problems of insufficient anchor cable pretightening force to constrain roof deformation or excessive pretightening force to damage the anchor cable due to fixed parameters, and improving the matching degree of anchor support and actual working conditions of the roof.

[0067] In the present embodiment, the precise tensioning control comprises:

[0068] sending the adjusted parameter instruction to the electric control main valve;

[0069] the electric control main valve controls the oil supply flow of the pneumatic oil pump, so that the corrected tensioning pressure gradually approaches the adjusted target pressure;

[0070] when the corrected tensioning pressure reaches the adjusted target pressure, the pressure stabilization stage is entered;

[0071] In the pressure stabilization stage, if the deviation of the corrected tensioning pressure from the adjusted target pressure exceeds the pressure deviation allowable range, the electric control main valve automatically supplements the pressure to the adjusted target pressure.

[0072] Specifically, the data processing unit converts the adjusted target pressure and the pressure stabilization time into corresponding electrical signal instructions and sends them to the electric control main valve of the automatic tensioning execution unit. After receiving the instructions, the electric control main valve controls the oil supply flow of the pneumatic oil pump by adjusting the valve opening. When the valve opening increases, the oil supply flow of the pneumatic oil pump to the anchor tensioning tool increases, and the corrected tensioning pressure gradually rises. When the valve opening is stable, the oil supply flow remains constant, and the corrected tensioning pressure gradually approaches the adjusted target pressure. When the corrected tensioning pressure reaches the adjusted target pressure, the electric control main valve maintains the current opening and enters the pressure stabilization stage. In the pressure stabilization stage, the data processing unit compares the corrected tensioning pressure with the adjusted target pressure in real time. If the deviation between the two exceeds the allowed pressure deviation range, the electric control main valve automatically increases the valve opening to control the pneumatic oil pump to increase the oil supply flow and supplement the oil circuit until the corrected tensioning pressure rises to the adjusted target pressure. This precise flow control and automatic pressure supplement mechanism can effectively avoid the problems of pressure overshoot or pressure decay in the pressure stabilization stage, ensuring that the anchor is always in the set pressure state during the pressure stabilization stage and improving the stability of the anchor pretensioning force.

[0073] In the present embodiment, the method further comprises:

[0074] After the end of the pressure stabilization stage, the adjusted target pressure, the actual pressure stabilization time, the roof pressure change curve and the corrected tensioning pressure curve of the present tensioning are stored.

[0075] Specifically, a mine data storage module is configured in the system, which has a stable data connection with the data processing unit and has the ability to resist the humid and dusty environment underground. After the end of the pressure stabilization stage, the data processing unit automatically extracts the key data in the present tensioning process, including the adjusted target pressure and the actual pressure stabilization time, and simultaneously calls the roof pressure change curve collected by the real-time monitoring unit and the corrected tensioning pressure curve after anti-interference processing. These data are transmitted to the data storage module in a pre-set format for storage, and the data storage module supports long-term storage and subsequent retrieval of data. Subsequent maintenance personnel can retrieve historical tensioning data through a data reading interface to analyze the correlation between anchor tensioning effect and roof stability under different working conditions, provide data reference for optimizing subsequent tensioning parameters and roadway support scheme, and further improve the reliability and rationality of roadway support.

[0076] Please refer to Figure 2 The present application also provides a coal mine tunneling roadway anchor automatic tensioning control system, comprising:

[0077] The automatic tensioning execution unit comprises a pneumatic oil pump, an electric control main valve and an anchor tensioning tool.

[0078] The real-time monitoring unit comprises a tensioning pressure sensor, a roof pressure sensor and an environmental interference sensor.

[0079] The data processing unit comprises an anti-interference filtering module and an adaptive parameter adjustment module.

[0080] The linkage control unit;

[0081] The automatic tensioning execution unit, the real-time monitoring unit, the data processing unit and the linkage control unit realize data interaction through the mine industrial ring network.

[0082] Specifically, the pneumatic oil pump in the automatic tensioning execution unit provides hydraulic power for the tensioning process, the electric control main valve is responsible for adjusting the pressure and flow of the oil circuit, and the anchor cable tensioning machine is directly connected with the anchor cable to perform tensioning and locking actions. The tensioning pressure sensor of the real-time monitoring unit is installed on the oil circuit pipeline to collect the hydraulic pressure original signal, the roof pressure sensor is arranged at the key point of the roof to collect the actual pressure of the rock stratum, and the environmental interference sensor is installed near the tensioning equipment to collect humidity and vibration frequency. The anti-interference filtering module of the data processing unit performs filtering processing on the tensioning pressure original signal, and the adaptive parameter adjustment module adjusts the tensioning parameters according to the roof pressure data. The linkage control unit is responsible for receiving abnormal signals and triggering early warning and equipment suspension instructions. The automatic tensioning execution unit, the real-time monitoring unit, the data processing unit and the linkage control unit are connected through the mine industrial ring network, the mine industrial ring network has the characteristics of strong anti-interference ability and stable data transmission, can realize real-time data interaction between units, ensures the rapid transmission of tensioning parameter adjustment instructions, early warning signals and equipment control signals, guarantees the collaborative work of each part of the system, and improves the efficiency and safety of the overall tensioning control.

[0083] In the embodiment, the real-time monitoring unit comprises:

[0084] The tensioning pressure sensor is used for collecting the hydraulic pressure original signal of the tensioning process in real time.

[0085] The roof pressure sensor is used for collecting the actual pressure of the roof rock stratum in real time.

[0086] The environmental interference sensor is used for synchronously collecting the humidity and vibration frequency underground.

[0087] Specifically, the tensioning pressure sensor contained in the real-time monitoring unit adopts a hydraulic detection structure, is installed on an oil path pipeline between the pneumatic oil pump and the anchor cable tensioning device, has a sensing end directly contacting hydraulic oil in the oil path, collects a hydraulic pressure original signal in a tensioning process in real time, and converts the original signal into an electrical signal and transmits the electrical signal to the data processing unit. The roof pressure sensor adopts a contact type design, is installed at a key support point of a roadway roof through a fixed support, has a sensor detection surface closely combined with the roof strata, collects actual pressure data of the roof strata in real time, and ensures that the data can reflect a real stress state of the roof. The environmental interference sensor integrates humidity detection and vibration detection functions, is installed on a roadway side wall at a distance of 1 m to 3 m from the tensioning device, avoids the influence of device self-vibration on detection results, synchronously collects humidity and vibration frequency data in an underground environment, and transmits the data to the data processing unit in real time to provide interference coefficients for anti-interference filtering processing.

[0088] In the embodiment, the data processing unit includes:

[0089] The anti-interference filtering module is configured to perform Kalman filtering processing on the original signal of the tensioning pressure sensor by taking the humidity and vibration frequency data collected by the environmental interference sensor as interference coefficients, to obtain a corrected tensioning pressure.

[0090] The adaptive parameter adjustment module is configured to adjust tensioning parameters, including a target pressure and a pressure stabilization time, according to a comparison result of the real-time roof pressure collected by the roof pressure sensor and a preset roof pressure safety threshold.

[0091] Specifically, the anti-interference filtering module of the data processing unit preloads a filtering model, takes the humidity and vibration frequency as interference coefficients after receiving the humidity and vibration frequency data transmitted by the environmental interference sensor, subsequently receives the original signal transmitted by the tensioning pressure sensor, processes the original signal by using a Kalman filtering algorithm, filters interference components in the original signal, and obtains the corrected tensioning pressure. The adaptive parameter adjustment module stores a preset roof pressure safety threshold, receives real-time roof pressure data collected by the roof pressure sensor in real time, compares the real-time roof pressure with the safety threshold, generates an adjustment instruction of increasing the tensioning target pressure and prolonging the pressure stabilization time if the real-time roof pressure is greater than an upper limit of the safety threshold, generates an adjustment instruction of reducing the tensioning target pressure and shortening the pressure stabilization time if the real-time roof pressure is less than a lower limit of the safety threshold, and generates an instruction of keeping the initial tensioning parameters if the real-time roof pressure is within the safety threshold range, and subsequently transmits the adjustment instruction to the automatic tensioning execution unit.

[0092] In the embodiment, the linkage control unit is connected with the data processing unit, the underground sound and light alarm and the control end of the tunneling equipment through the RS485 bus, and is used for triggering the underground sound and light alarm to send a warning signal and sending a pause signal to the tunneling equipment when the real-time roof pressure exceeds the roof pressure safety threshold or the deviation of the corrected tension pressure from the adjusted target pressure continuously exceeds the pressure deviation allowable range.

[0093] Specifically, the linkage control unit constructs a data transmission path through the RS485 bus, one end of the bus is connected with the signal output end of the data processing unit, and the other end is respectively connected with the control end of the underground sound and light alarm and the signal receiving end of the control end of the tunneling equipment. When the data processing unit detects that the real-time roof pressure exceeds the preset safety threshold or the deviation of the corrected tension pressure from the adjusted target pressure continuously exceeds the allowable range, an abnormal triggering signal is immediately sent to the linkage control unit. After receiving the abnormal signal, the linkage control unit sends a starting instruction to the underground sound and light alarm through the RS485 bus, and the sound and light alarm sends a sound and light warning signal to prompt the on-site personnel after receiving the instruction. At the same time, the linkage control unit sends a pause instruction to the control end of the tunneling equipment through the bus, and the control end of the tunneling equipment controls the equipment to stop working after receiving the instruction, and the working state is resumed only after the abnormal condition is eliminated, thereby ensuring the safety of the underground operation personnel and equipment.

[0094] In the embodiment, all components in the automatic tensioning execution unit, the real-time monitoring unit, the data processing unit and the linkage control unit are designed in a mine explosion-proof type or a mine intrinsic safety type.

[0095] Specifically, the pneumatic oil pump in the automatic tensioning execution unit is designed in a mine explosion-proof type, the shell thereof is made of high-strength alloy material and has sufficient mechanical strength to withstand the internal explosion pressure, and the shell joint surface meets the explosion-proof gap requirement and can prevent the explosion flame from spreading to the external environment; the electric control main valve is also designed in a mine explosion-proof type, the internal circuit is isolated from the external explosion-proof shell to avoid the circuit spark from causing a safety accident; and the key transmission components of the anchor cable tensioning machine are treated in an explosion-proof manner to ensure that no ignition spark is generated during the tensioning process. The tensioning pressure sensor and the environmental interference sensor in the real-time monitoring unit are designed in a mine intrinsic safety type, the internal circuit of the sensor is specially designed, and the electric spark and thermal effect generated in the normal working and fault states will not ignite the underground explosive gas mixture. The core circuit board of the data processing unit and the linkage control unit is designed in a mine intrinsic safety type, and the external shell is designed in a mine explosion-proof type, thereby forming double safety protection. The design of all components meets the coal mine underground explosion-proof safety standard, ensures the safe operation of the system in the environment with high humidity, dust and explosive gas in the coal mine, and avoids causing a safety accident.

[0096] In conclusion, the present application effectively solves the problems of pressure signal attenuation and high-frequency fluctuation caused by complex downhole environment by collecting environmental interference data such as downhole humidity and vibration frequency, combining anti-interference filtering processing to correct the original tension pressure signal, and ensuring the accuracy of tension pressure data; according to the comparison result of real-time roof pressure and safety threshold, the tension target pressure and pressure stabilization time are adaptively adjusted to avoid the problems of insufficient or excessive anchor cable pretightening force caused by fixed parameters of the existing system; when the roof pressure is out of limit or the tension pressure deviation continuously exceeds the allowed range, the linkage early warning is triggered and the pause signal is sent to the tunneling equipment, filling the gap of the lack of linkage correction mechanism in the existing system, while storing the tension key data to provide support for subsequent optimization, and overall improving the anchor cable tension control precision, roof support adaptability and downhole operation safety, ensuring the stability of the roadway roof.

[0097] It should be noted that, in this document, the terms such as first and second are used merely to distinguish one entity or action from another, and do not necessarily require or imply that these entities or actions occur in any such actual relationship or order. Moreover, the terms "include", "contain" or any other variants thereof are intended to cover non-exclusive inclusion, so that the process, method, article or equipment including a series of elements not only includes those elements, but also includes other elements not explicitly listed or inherent to such process, method, article or equipment.

[0098] Although embodiments of the present application have been shown and described, it will be understood by those having ordinary skill in the art that various changes, modifications, alternatives and variations can be made thereto without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A method for automatic tensioning control of anchor cables in coal mine tunneling roadways, characterized in that, include: Initialize the tensioning parameters, the safety threshold for top plate pressure, and the allowable range for pressure deviation; Real-time acquisition of raw tension pressure signals, real-time top plate pressure, and environmental interference data, including humidity and vibration frequency; The original tension pressure signal is subjected to anti-interference filtering to obtain the corrected tension pressure. Based on the comparison between the real-time roof pressure and the roof pressure safety threshold, the tensioning parameters are adaptively adjusted. The tensioning parameters include the target pressure and the stabilization time. Precise tension control is performed based on the adjusted tension parameters to gradually bring the corrected tension pressure closer to the adjusted target pressure. When the corrected tension pressure reaches the adjusted target pressure, the pressure stabilization stage begins. After the pressure stabilization phase is completed, lock the anchor cable; If the real-time roof pressure exceeds the roof pressure safety threshold, or if the deviation between the corrected tension pressure and the adjusted target pressure continues to exceed the allowable pressure deviation range, a linkage early warning signal will be triggered, and a pause signal will be sent to the tunneling equipment.

2. The automatic tensioning control method for anchor cables in coal mine tunneling roadways according to claim 1, characterized in that, The anti-interference filtering process includes: Call the Kalman filter algorithm; A filtering model was established using humidity and vibration frequency as interference coefficients. The original tension pressure signal is processed to obtain the corrected tension pressure.

3. The automatic tensioning control method for anchor cables in coal mine tunneling roadways according to claim 1, characterized in that, The adaptive adjustment of tensioning parameters includes: If the real-time top pressure is greater than the upper limit of the top pressure safety threshold, then increase the tensioning target pressure and extend the pressure stabilization time; If the real-time top pressure is less than the lower limit of the top pressure safety threshold, then reduce the tensioning target pressure and shorten the pressure stabilization time; If the real-time roof pressure is within the safe threshold range of roof pressure, then the initial tensioning parameters remain unchanged.

4. The automatic tensioning control method for anchor cables in coal mine tunneling roadways according to claim 1, characterized in that, The precise tension control includes: Send the adjusted parameter command to the electronically controlled main valve; The electronically controlled main valve controls the oil supply flow of the pneumatic oil pump, so that the corrected tensioning pressure gradually approaches the adjusted target pressure. When the corrected tensioning pressure reaches the adjusted target pressure, the pressure stabilization phase begins. During the pressure stabilization phase, if the deviation between the corrected tension pressure and the adjusted target pressure exceeds the allowable range of pressure deviation, the electrically controlled main valve will automatically replenish the pressure to the adjusted target pressure.

5. The automatic tensioning control method for anchor cables in coal mine tunneling roadways according to claim 1, characterized in that, The method also includes: After the pressure stabilization phase is completed, the adjusted target pressure, actual pressure stabilization time, top plate pressure change curve, and corrected tensioning pressure curve for this tensioning are stored.

6. An automatic tensioning control system for anchor cables in coal mine tunneling roadways, applied to the automatic tensioning control method for anchor cables in coal mine tunneling roadways as described in any one of claims 1-5, characterized in that, The system includes: An automatic tensioning execution unit, comprising a pneumatic oil pump, an electrically controlled main valve, and an anchor cable tensioning device; A real-time monitoring unit, comprising a tension pressure sensor, a top plate pressure sensor, and an environmental interference sensor; The data processing unit includes an anti-interference filtering module and an adaptive parameter adjustment module; Linkage control unit; The automatic tensioning execution unit, the real-time monitoring unit, the data processing unit, and the linkage control unit all achieve data interaction through the mining industrial ring network.

7. The automatic tensioning control system for anchor cables in coal mine tunneling as described in claim 6, characterized in that, The real-time monitoring unit includes: The tension pressure sensor is used to collect the raw hydraulic pressure signal during the tensioning process in real time. The roof pressure sensor is used to collect the actual pressure of the roof rock strata in real time; The environmental interference sensor is used to synchronously collect downhole humidity and vibration frequency.

8. The automatic tensioning control system for anchor cables in coal mine tunneling as described in claim 6, characterized in that, The data processing unit includes: The anti-interference filtering module is used to perform Kalman filtering on the original signal of the tension pressure sensor using the humidity and vibration frequency data collected by the environmental interference sensor as interference coefficients, so as to obtain the corrected tension pressure. The adaptive parameter adjustment module is used to adjust the tensioning parameters based on the comparison between the real-time roof pressure collected by the roof pressure sensor and the preset roof pressure safety threshold. The tensioning parameters include the target pressure and the stabilization time.

9. The automatic tensioning control system for anchor cables in coal mine tunneling as described in claim 6, characterized in that, The linkage control unit is connected to the data processing unit, the underground audible and visual alarm, and the tunneling equipment control terminal via an RS485 bus. When the real-time roof pressure exceeds the roof pressure safety threshold, or when the deviation between the corrected tension pressure and the adjusted target pressure continues to exceed the allowable pressure deviation range, the underground audible and visual alarm is triggered to issue a warning signal and a pause signal is sent to the tunneling equipment.

10. The automatic tensioning control system for anchor cables in coal mine tunneling as described in claim 6, characterized in that, All components in the automatic tensioning execution unit, real-time monitoring unit, data processing unit, and linkage control unit are designed for mining explosion-proof or intrinsically safe applications.

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