High-efficiency multi-stage energy-saving remote intelligent liquid supply system for coal mine

Abstract

The invention discloses a high-efficiency multi-stage energy-saving remote intelligent liquid supply system for a coal mine, and relates to the technical field of underground hydraulic liquid supply of the coal mine, which comprises a liquid supply power module adopting a multi-pump parallel cluster structure; the working condition sensing module is used for collecting underground multi-dimensional dynamic working condition data; the energy-saving regulation and control module integrates a working condition prediction unit, an on-way resistance compensation unit and a pump set cluster cooperation unit, and the working condition prediction unit calculates the optimal liquid supply flow; the on-way resistance compensation unit calculates accurate compensation pressure; the pump set cluster cooperation unit realizes optimal distribution of multi-pump loads; the long-distance conveying module comprises a high-pressure-resistant pipeline, a tail end pressure regulating valve set and a filtering assembly. The central control unit drives the energy-saving regulation and control module to calculate the optimal liquid supply flow and controls the liquid supply power module to adjust output to be in linkage with the tail end pressure regulating valve set to complete pressure compensation. The technical problems that an existing liquid supply system is static in energy-saving design and not thorough in energy consumption optimization are solved, and the energy-saving efficiency and operation stability of the system are improved.

Description

Technical Field

[0001] This invention relates to the field of hydraulic fluid supply technology in underground coal mines, and more specifically, to a high-efficiency, multi-stage, energy-saving, long-distance intelligent fluid supply system for coal mines. Background Technology

[0002] In the process of intelligent coal mining, a high-efficiency and stable long-distance fluid supply system is the core support for ensuring continuous operation of fully mechanized mining faces. Although existing high-efficiency multi-stage energy-saving long-distance intelligent fluid supply systems in coal mines have introduced basic energy-saving measures such as variable frequency speed regulation, their energy-saving design still has significant "static" limitations.

[0003] Shortcomings of existing technology: Existing systems rely on preset thresholds for working face conditions to adjust pressure / flow, such as increasing the flow output during support movement. However, actual underground fluid demand fluctuates dynamically—the support resistance of hydraulic supports varies in different areas, and the instantaneous load of the coal mining machine cutting coal and rock changes in real time. The preset thresholds cannot accurately match the dynamic demand, resulting in a mismatch between the fluid supply parameters and the actual fluid consumption, leading to "over-supply" and wasted energy. According to industry statistics, the extra energy consumption under this static adjustment mode accounts for as much as 8% to 12%.

[0004] Existing systems only reduce basic transport resistance by optimizing pipeline materials (such as using nano-ceramic coated pipelines), without considering the dynamic changes in friction resistance along the downhole pipeline. When siltation or sudden changes in local resistance occur in the pipeline at the initial stage of leakage, the original fixed pressure compensation strategy may result in over- or under-compensation, leading to energy waste and affecting the stability of the end-point fluid supply. High-flow pump sets mostly use a single variable frequency speed control method to achieve energy saving, without constructing a pump set cluster collaborative control mechanism. When a system supplies fluid to multiple working faces simultaneously, it is easy to encounter situations of inefficient operation of "large pumps under small loads" or "multiple pumps superimposed redundant fluid supply," resulting in a decrease in pump set transmission efficiency—the energy saving rate of a single pump variable frequency is about 15%~20%, but the energy saving rate drops sharply to 5%~8% when running in a cluster, and the energy saving potential is not fully released.

[0005] To address the above problems, this invention proposes a solution. Summary of the Invention

[0006] To overcome the aforementioned deficiencies of the prior art, embodiments of the present invention provide a high-efficiency, multi-stage, energy-saving, long-distance intelligent liquid supply system for coal mines. Through dynamic operating condition prediction, real-time compensation for friction loss, and coordinated control of pump clusters, the system achieves precise matching between liquid supply parameters and actual needs, significantly reducing additional energy consumption and improving system energy efficiency and operational stability, thereby solving the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: A high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines includes a liquid supply power module, a working condition sensing module, an energy-saving control module, a long-distance conveying module, and a central control unit, with connections between the modules. The liquid supply power module adopts a multi-pump parallel cluster structure, and each pump is equipped with an independent frequency conversion drive unit; The working condition sensing module is used to collect multi-dimensional dynamic working condition data from the well and transmit it to the central control unit. The energy-saving control module integrates a working condition prediction unit, a friction resistance compensation unit, and a pump group cluster coordination unit. The working condition prediction unit integrates dynamic working condition data and calculates the optimal liquid supply flow rate through a liquid demand prediction model. The friction resistance compensation unit calculates the accurate compensation pressure through a dynamic resistance compensation formula. The pump group cluster coordination unit achieves optimal load distribution among multiple pumps through a load distribution formula. The long-distance conveying module includes a high-pressure resistant pipeline, an end pressure regulating valve group, and a filter assembly. The end pressure regulating valve group is linked with the friction resistance compensation unit. The central control unit drives the energy-saving regulation module to calculate the optimal liquid supply flow rate, controls the liquid supply power module to adjust the output of the linkage terminal pressure regulating valve group to complete pressure compensation, and realizes dynamic, precise and energy-saving liquid supply.

[0008] In a preferred embodiment, the multi-pump parallel cluster adopts a redundant cluster architecture of main pump + standby pump, wherein the number of main pumps is configured according to the maximum liquid supply demand, and the number of standby pumps is at least one and the specifications are consistent with the main pumps; all pump groups are connected in parallel through a manifold, which has a built-in pressure sensor and a check valve. The check valve can prevent emulsion backflow when a single pump fails, and the pressure sensor collects the total output pressure of the cluster in real time and feeds it back to the central control unit.

[0009] In a preferred embodiment, the independent variable frequency drive unit consists of a frequency converter, a PLC sub-controller, and a heat dissipation assembly; the frequency converter is a vector control type frequency converter; the PLC sub-controller is responsible for receiving instructions from the central control unit, parsing them, and converting them into speed control signals for the frequency converter, while simultaneously acquiring the current, voltage, and speed data of the motor in real time to achieve closed-loop control; the heat dissipation assembly adopts a forced air cooling + water cooling composite heat dissipation structure to ensure stable operation of the frequency converter in the high-temperature environment underground.

[0010] In a preferred embodiment, the liquid supply power module performs the following steps: Each pump unit's variable frequency drive unit receives flow and pressure regulation commands from the central control unit via industrial Ethernet. The commands include the target output flow, target output pressure, and the number of pump units in operation. The PLC sub-controller parses the instructions and, in conjunction with the real-time motor data it collects, determines whether the operating status needs to be adjusted. According to the parsed instructions, the variable frequency drive unit outputs AC power of the appropriate frequency through the frequency converter to adjust the speed of the pump motor; at the same time, it monitors the pump outlet pressure and dynamically fine-tunes the speed to ensure that the output pressure of a single pump is stable within the target range. Under the unified scheduling of the pump group cluster coordination unit, multiple main pumps operate in coordination according to the allocated load parameters; The central control unit monitors the operating status of each main pump in real time. When a fault is detected in a main pump, it immediately sends a command to the variable frequency drive unit of the standby pump to start the standby pump and issues a fault alarm signal.

[0011] In a preferred embodiment, the working condition sensing module includes a coal mining machine load sensor, a hydraulic support resistance sensor, a roof pressure sensor, and a pipeline friction resistance sensor. The coal mining machine load sensor collects the real-time cutting load of the coal mining machine; the hydraulic support resistance sensor collects the real-time support resistance of the support in each area; the roof pressure sensor collects the roof pressure in different sections of the working face; and the pipeline friction resistance sensor collects real-time friction resistance data. The collected multi-dimensional dynamic operating condition data is transmitted to the central control unit in real time via industrial Ethernet, providing data support for parameter calculation of the energy-saving control module.

[0012] In a preferred embodiment, the operating condition prediction unit integrates dynamic operating condition data and calculates the optimal liquid supply flow rate using a liquid demand prediction model, as follows: Receive dynamic operating condition data collected by the operating condition sensing module and forwarded by the central control unit; Based on the matching relationship between dynamic working condition data and preset thresholds, three key coefficients are derived: coal mining machine load coefficient, support action coefficient, and roof pressure coefficient. The optimal fluid supply flow rate is calculated using a fluid demand prediction model based on the coal mining machine load factor, support movement factor, roof pressure factor, and foundation fluid supply flow rate. The calculation formula is as follows: In the formula, To achieve the optimal liquid supply flow rate; Basic liquid supply flow rate; It is the load factor of the coal mining machine; It is the stent's action coefficient; It is the pressure coefficient of the roof slab; The calculated optimal fluid supply flow rate is transmitted to the friction resistance compensation unit and the pump group cluster coordination unit.

[0013] In a preferred embodiment, the friction loss compensation unit calculates the accurate compensation pressure using a dynamic friction loss compensation formula, as follows: Receive real-time pipeline friction resistance data transmitted by the working condition sensing module, and the optimal fluid supply flow rate output by the working condition prediction unit. The resistance fluctuation coefficient is calculated based on the ratio of real-time friction support resistance data to the preset resistance per unit length of pipeline foundation. Obtain the actual conveying distance and the rated liquid supply pressure at the end of the working face, and calculate the compensated pressure that the pump set needs to output using the dynamic resistance compensation formula, based on the resistance fluctuation coefficient. The calculation formula is as follows: In the formula, , The rated liquid supply pressure at the end of the working face, L is the foundation resistance per unit length of pipeline. , This is the resistance fluctuation coefficient; After calculating the compensation The data is transmitted to the central control unit, and a pressure regulation reference command is simultaneously sent to the end pressure regulating valve group of the long-distance delivery module.

[0014] In a preferred embodiment, the pump group cluster coordination unit achieves optimal load allocation among multiple pumps through a load allocation formula, as follows: It receives the optimal liquid supply flow rate output by the working condition prediction unit and the compensated pressure output by the friction resistance compensation unit, and simultaneously obtains the rated parameters and maximum transmission efficiency of each pump group in the liquid supply power module. The optimal output flow rate of each pump is calculated using a load distribution formula to ensure that the load of multiple pumps is balanced and the cluster operates in the highest efficiency range. Based on the optimal output flow of each pump, and combined with the compensated pressure, frequency conversion adjustment commands for each pump group are generated and transmitted to the central control unit.

[0015] In a preferred embodiment, the long-distance conveying module is implemented as follows: The high-pressure emulsion output from the power supply module is transported over long distances through high-strength, high-pressure-resistant pipelines. During the transport process, the emulsion is filtered through a three-stage filtration system to ensure its cleanliness and prevent wear on hydraulic components. The end pressure regulating valve group receives the adjustment command issued by the friction resistance compensation unit, and adjusts the valve group opening in real time in combination with the actual end pressure data it collects, so as to accurately compensate the delivery pressure. The compensated emulsion is stably delivered to the hydraulic equipment at the working face to ensure that the end-supply pressure is stable within the rated range and meets the equipment's working requirements.

[0016] In a preferred embodiment, the central control unit is implemented as follows: Receive all dynamic operating condition data transmitted by the operating condition sensing module and forward it to the operating condition prediction unit of the energy-saving control module; It receives the optimal liquid supply flow rate, compensated pressure, and optimal output flow rate of each pump group from the energy-saving control module, and integrates them to generate the frequency conversion adjustment command of the liquid supply power module. The variable frequency adjustment command of each pump group is sent to the liquid supply power module to control multiple pump groups to operate in coordination according to the optimal load parameters. At the same time, the pressure-related command after compensation is forwarded to the end pressure regulating valve group of the long-distance delivery module to complete the pressure compensation in a coordinated manner. The system monitors the operating status of each module in real time. When abnormal data transmission, pump failure, or deviation of liquid supply pressure / flow from the threshold is detected, an emergency response is immediately initiated to ensure stable system operation.

[0017] The technical effects and advantages of the present invention, a high-efficiency multi-stage energy-saving long-distance intelligent liquid supply system for coal mines: 1. This invention overcomes the limitations of static regulation, significantly reducing energy waste due to oversupply. Through dynamic fluid supply parameter optimization technology based on multi-dimensional operating condition prediction, it precisely matches fluid supply flow rate and pressure with real-time downhole fluid demand. The 8%~12% extra energy consumption under static regulation mode can be reduced by more than 60%, significantly improving energy efficiency. It achieves controllable energy consumption for long-distance transportation. Through dynamic pipeline resistance compensation technology, it responds in real-time to resistance changes caused by pipeline siltation and micro-leakage, avoiding over- or under-compensation of pressure. The terminal pressure fluctuation range is reduced from the existing ±0.5MPa to ±0.1MPa, both reducing transportation energy loss and improving fluid supply stability.

[0018] 2. This invention optimizes the load distribution of multiple pumps through pump cluster collaborative control technology, increasing the energy-saving rate of pump cluster operation from the current 5%~8% to 18%~22%, fully releasing the energy-saving potential of the pumps. The dynamic load distribution mechanism can flexibly adapt to the simultaneous liquid supply needs of multiple working faces, allocating liquid supply resources according to the real-time operating conditions of each working face, avoiding the problem of redundant liquid supply to a single working face and insufficient liquid supply to other working faces, thereby improving the overall operating efficiency of the system. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of a high-efficiency, multi-stage, energy-saving, long-distance intelligent liquid supply system for coal mines according to the present invention. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] To address the technical shortcomings of existing long-distance liquid supply systems in coal mines, such as static energy-saving design and incomplete energy consumption optimization, this invention provides a high-efficiency, multi-stage, energy-saving, long-distance intelligent liquid supply system for coal mines. Through dynamic operating condition prediction, real-time compensation for friction loss, and coordinated control of pump clusters, it achieves precise matching of liquid supply parameters with actual needs, significantly reducing additional energy consumption and improving system energy efficiency and operational stability.

[0022] Example 1, Figure 1 This invention presents a high-efficiency, multi-stage, energy-saving, long-distance intelligent liquid supply system for coal mines.

[0023] The liquid supply power module adopts a multi-pump parallel cluster structure, and each pump is equipped with an independent frequency conversion drive unit; The multi-pump parallel cluster adopts a redundant cluster architecture of "main pump + standby pump". The number of main pumps is configured according to the maximum liquid supply demand (usually 2 to 4 units), and the number of standby pumps is at least 1 and the specifications are the same as the main pumps. All pump groups are connected in parallel through manifold. The manifold has built-in pressure sensors and check valves. The check valve can prevent emulsion backflow when a single pump fails. The pressure sensor collects the total output pressure of the cluster in real time and feeds it back to the central control unit.

[0024] Each main pump and standby pump is equipped with an independent variable frequency drive unit. This unit consists of a frequency converter, a PLC sub-controller, and a heat dissipation component. The frequency converter adopts a vector control type, which supports a wide frequency adjustment range of 0~50Hz to meet the speed regulation requirements of the pump group motor. The PLC sub-controller is responsible for receiving instructions from the central control unit, parsing them, and converting them into speed regulation signals for the frequency converter. At the same time, it collects the current, voltage, and speed data of the motor in real time to achieve closed-loop control. The heat dissipation component adopts a forced air cooling + water cooling composite heat dissipation structure to ensure stable operation of the frequency converter in the high-temperature environment (40~60℃) underground.

[0025] The liquid supply power module performs the following steps: Each pump unit's variable frequency drive unit receives flow and pressure adjustment commands from the central control unit via industrial Ethernet. The commands include the target output flow, target output pressure, and the number of pump units in operation. The PLC sub-controller parses the commands and, in conjunction with the real-time motor data it collects, determines whether the operating status needs to be adjusted. According to the parsed instructions, the variable frequency drive unit outputs AC power of the appropriate frequency through the frequency converter to adjust the speed of the pump motor. Since the pump output flow rate is linearly positively correlated with the motor speed, precise control of the single pump output flow rate can be achieved by precisely adjusting the speed. At the same time, by monitoring the pump outlet pressure and dynamically fine-tuning the speed, the single pump output pressure is ensured to remain stable within the target range, thus achieving precise "flow-pressure" dual closed-loop regulation. Under the unified scheduling of the pump cluster coordination unit, multiple main pumps operate collaboratively according to the assigned load parameters. Based on the optimal fluid supply flow rate requirement, some main pumps operate in the rated load range, while others operate in the adjustable load range, avoiding the efficiency decline caused by long-term low-load operation of a single pump. The manifold aggregates the emulsion output from each pump to form a stable total flow rate and total pressure output, meeting the dynamic fluid demand in the well. During operation, the pressure sensor on the manifold provides real-time feedback of total pressure data, providing a basis for the central control unit's regulation. The central control unit monitors the operating status of each main pump in real time (current, voltage, speed, and pump outlet pressure data fed back by the frequency converter drive unit). When a fault is detected in a main pump (such as motor overload, pump body leakage, or abnormal pressure), it immediately sends a command to the frequency converter drive unit of the standby pump to start the standby pump. At the same time, a fault alarm signal is issued and pushed to the ground monitoring center via industrial Ethernet, and the relevant data of the faulty pump group is recorded. After the standby pump starts, the frequency converter drive unit quickly adjusts the speed to match the output flow and pressure of the standby pump with the original faulty pump, ensuring that the total output parameters of the cluster are stable and without significant fluctuations, thus ensuring the continuity of liquid supply.

[0026] The working condition sensing module includes a coal mining machine load sensor, a hydraulic support resistance sensor, a roof pressure sensor, and a pipeline friction resistance sensor, which are used to collect multi-dimensional dynamic working condition data underground and transmit it to the central control unit. The coal mining machine load sensor is installed at the power output end of the coal mining machine. The hydraulic support resistance sensor is deployed in the working face support area (one group of 5 supports). The roof pressure sensor is deployed in the working face every 100 meters. The pipeline friction resistance sensor is deployed every 1 km on the long-distance conveying pipeline. Each sensor collects data in real time in its corresponding dimension. Specifically, the coal mining machine load sensor collects the real-time cutting load of the coal mining machine, the hydraulic support resistance sensor collects the real-time support resistance of the support in each area, the roof pressure sensor collects the roof pressure in different sections of the working face, and the pipeline friction resistance sensor collects real-time friction resistance data. The collected multi-dimensional dynamic operating condition data is transmitted to the central control unit in real time via industrial Ethernet, providing data support for parameter calculation of the energy-saving control module.

[0027] The energy-saving control module integrates a working condition prediction unit, a friction resistance compensation unit, and a pump group cluster coordination unit. The working condition prediction unit integrates dynamic working condition data and calculates the optimal liquid supply flow rate through a liquid demand prediction model. The friction resistance compensation unit calculates the accurate compensation pressure through a dynamic resistance compensation formula. The pump group cluster coordination unit achieves optimal load distribution among multiple pumps through a load distribution formula. The operating condition prediction unit integrates dynamic operating condition data and calculates the optimal liquid supply flow rate using a liquid demand prediction model. The process is as follows: It receives data collected by the working condition sensing module forwarded by the central control unit and integrates three core dynamic data: coal mining machine load, support resistance, and roof pressure. Based on the matching relationship between the collected data and the preset threshold, three key coefficients are derived: coal mining machine load coefficient, support action coefficient, and roof pressure coefficient. The process of deriving three key coefficients based on the matching relationship between the collected data and preset thresholds is as follows: Coal mining machine load factor Real-time cutting load is collected by the coal mining machine's load sensor and compared with the rated load of the coal mining machine for conversion: no-load (load) The coefficient for rated load is 0.8; for rated load (80%~100% of rated load), it is 1.0; for overload (load > 120% of rated load, cutting hard rock), it is 1.5; the support action coefficient is... The calculation is based on the changes in resistance and the action status collected by the hydraulic support resistance sensor: For a single independent support movement (single support resistance change and displacement sensor trigger), a value of 1.2 is used; for multiple supports moving synchronously... A coefficient of 2.0 is used when a sudden change in resistance occurs, and a coefficient of 0.5 is used when all supports are stable (resistance stabilizes at the safe threshold, with no displacement); the roof pressure coefficient is... : Compare and convert the pressure data collected by the top plate pressure sensor with the safety warning threshold: Pressure The warning threshold (safety status) is set to 0.9, pressure. The warning threshold (approaching danger) is set to 1.3.

[0028] The optimal fluid supply flow rate is calculated using a fluid demand prediction model based on the coal mining machine load factor, support movement factor, roof pressure factor, and foundation fluid supply flow rate. The calculation formula is as follows: In the formula, To achieve the optimal liquid supply flow rate; Basic liquid supply flow rate; It is the load factor of the coal mining machine; It is the stent's action coefficient; It is the pressure coefficient of the roof slab; The calculated optimal fluid supply flow rate is transmitted to the friction resistance compensation unit and the pump group cluster coordination unit.

[0029] The friction loss compensation unit calculates the precise compensation pressure using a dynamic resistance compensation formula, as follows: Receive real-time pipeline friction resistance data transmitted by the working condition sensing module, and the optimal fluid supply flow rate output by the working condition prediction unit. The resistance fluctuation coefficient is calculated based on the ratio of real-time friction support resistance data to the preset resistance per unit length of pipeline foundation. Obtain the actual conveying distance and the rated liquid supply pressure at the end of the working face, and calculate the compensated pressure that the pump set needs to output using the dynamic resistance compensation formula, based on the resistance fluctuation coefficient. The calculation formula is as follows: In the formula, , The rated fluid supply pressure at the end of the working face (unit: MPa, set according to the rated working pressure of the hydraulic support). The base resistance per unit length of pipeline (unit: MPa / km, preset according to pipeline material, such as 0.2 MPa / km for nano-ceramic coated pipelines), L , This is the resistance fluctuation coefficient; After calculating the compensation The data is transmitted to the central control unit, and a pressure regulation reference command is simultaneously sent to the end pressure regulating valve group of the long-distance delivery module.

[0030] The pump group cluster coordination unit achieves optimal load allocation among multiple pumps through a load distribution formula, as follows: It receives the optimal liquid supply flow rate output by the working condition prediction unit and the compensated pressure output by the friction resistance compensation unit, and simultaneously obtains the rated parameters and maximum transmission efficiency of each pump group in the liquid supply power module. The optimal output flow rate of each pump is calculated using a load distribution formula to ensure that the load of multiple pumps is balanced and the cluster operates in the highest efficiency range. Based on the optimal output flow of each pump, and combined with the compensated pressure, frequency conversion adjustment commands for each pump group are generated and transmitted to the central control unit.

[0031] The long-distance conveying module includes a high-pressure resistant pipeline, an end pressure regulating valve group, and a filter assembly. The end pressure regulating valve group is linked with the friction resistance compensation unit. The high-pressure emulsion output by the power supply module is transported over long distances through high-strength, high-pressure-resistant pipelines. During the transportation process, the emulsion is filtered through a three-stage filtration system to ensure its cleanliness and prevent wear on hydraulic components. The end pressure regulating valve group receives the adjustment command issued by the friction resistance compensation unit, and adjusts the valve group opening in real time in combination with the actual end pressure data it collects, so as to accurately compensate the delivery pressure. The compensated emulsion is stably delivered to the hydraulic equipment at the working face to ensure that the end-supply pressure is stable within the rated range and meets the equipment's working requirements.

[0032] The central control unit drives the energy-saving regulation module to calculate the optimal liquid supply flow rate, controls the liquid supply power module to adjust the output of the linkage terminal pressure regulating valve group to complete pressure compensation, and realizes dynamic, precise and energy-saving liquid supply.

[0033] Central control unit: As the core of the system, it drives the energy-saving control module to calculate optimal parameters, controls the liquid supply power module to adjust the output, and links the terminal pressure regulating valve group to complete pressure compensation. The specific working steps are as follows: Receive all dynamic operating condition data transmitted by the operating condition sensing module and forward it to the operating condition prediction unit of the energy-saving control module; It receives the optimal liquid supply flow rate, compensated pressure, and optimal output flow rate of each pump group from the energy-saving control module, and integrates them to generate the frequency conversion adjustment command of the liquid supply power module. The variable frequency adjustment command of each pump group is sent to the liquid supply power module to control multiple pump groups to operate in coordination according to the optimal load parameters. At the same time, the pressure-related command after compensation is forwarded to the end pressure regulating valve group of the long-distance delivery module to complete the pressure compensation in a coordinated manner. The system monitors the operating status of each module in real time. When abnormal data transmission, pump failure, or deviation of liquid supply pressure / flow from the threshold is detected, an emergency response is immediately initiated (such as switching to a backup pump, adjusting the opening of the pressure regulating valve group, and issuing an alarm signal) to ensure stable system operation and ultimately achieve dynamic, precise, and energy-saving liquid supply.

[0034] The above formulas are all dimensionless calculations. The formulas are derived from software simulations based on a large amount of collected data to obtain the most recent real-world results. The preset parameters in the formulas are set by those skilled in the art according to the actual situation.

[0035] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, in the form of a computer program product.

[0036] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0037] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0038] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0039] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-efficiency, multi-stage, energy-saving, long-distance intelligent liquid supply system for coal mines, comprising a liquid supply power module, a working condition sensing module, an energy-saving control module, a long-distance conveying module, and a central control unit, wherein the modules are interconnected: The liquid supply power module adopts a multi-pump parallel cluster structure, and each pump is equipped with an independent frequency conversion drive unit; The working condition sensing module is used to collect multi-dimensional dynamic working condition data from the well and transmit it to the central control unit. The energy-saving control module integrates a working condition prediction unit, a friction resistance compensation unit, and a pump group cluster coordination unit. The working condition prediction unit integrates dynamic working condition data and calculates the optimal liquid supply flow rate through a liquid demand prediction model. The friction resistance compensation unit calculates the accurate compensation pressure through a dynamic resistance compensation formula. The pump group cluster coordination unit achieves optimal load distribution among multiple pumps through a load distribution formula. The long-distance conveying module includes a high-pressure resistant pipeline, an end pressure regulating valve group, and a filter assembly. The end pressure regulating valve group is linked with the friction resistance compensation unit. The central control unit drives the energy-saving regulation module to calculate the optimal liquid supply flow rate, controls the liquid supply power module to adjust the output of the linkage terminal pressure regulating valve group to complete pressure compensation, and realizes dynamic, precise and energy-saving liquid supply.

2. The high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines according to claim 1, characterized in that, The multi-pump parallel cluster adopts a redundant cluster architecture of main pump + standby pump. The number of main pumps is configured according to the maximum liquid supply demand, and the number of standby pumps is at least one and the specifications are the same as the main pumps. All pump groups are connected in parallel through a manifold. The manifold has a built-in pressure sensor and a check valve. The check valve can prevent the emulsion from flowing back when a single pump fails. The pressure sensor collects the total output pressure of the cluster in real time and feeds it back to the central control unit.

3. The high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines according to claim 2, characterized in that, The independent frequency converter drive unit consists of a frequency converter, a PLC sub-controller, and a heat dissipation component. The frequency converter adopts a vector control type. The PLC sub-controller is responsible for receiving instructions from the central control unit, parsing them, and converting them into speed control signals for the frequency converter. At the same time, it collects the current, voltage, and speed data of the motor in real time to achieve closed-loop control. The heat dissipation component adopts a forced air cooling + water cooling composite heat dissipation structure to ensure stable operation of the frequency converter in the high-temperature environment underground.

4. The high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines according to claim 3, characterized in that, The liquid supply power module performs the following steps: Each pump unit's variable frequency drive unit receives flow and pressure regulation commands from the central control unit via industrial Ethernet. The commands include the target output flow, target output pressure, and the number of pump units in operation. The PLC sub-controller parses the instructions and, in conjunction with the real-time motor data it collects, determines whether the operating status needs to be adjusted. According to the parsed instructions, the variable frequency drive unit outputs AC power of the appropriate frequency through the frequency converter to adjust the speed of the pump motor; at the same time, it monitors the pump outlet pressure and dynamically fine-tunes the speed to ensure that the output pressure of a single pump is stable within the target range. Under the unified scheduling of the pump group cluster coordination unit, multiple main pumps operate in coordination according to the allocated load parameters; The central control unit monitors the operating status of each main pump in real time. When a fault is detected in a main pump, it immediately sends a command to the variable frequency drive unit of the standby pump to start the standby pump and issues a fault alarm signal.

5. The high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines according to claim 4, characterized in that, The working condition sensing module includes a coal mining machine load sensor, a hydraulic support resistance sensor, a roof pressure sensor, and a pipeline friction resistance sensor. The coal mining machine load sensor collects the real-time cutting load of the coal mining machine; the hydraulic support resistance sensor collects the real-time support resistance of the support in each area; the roof pressure sensor collects the roof pressure in different sections of the working face; and the pipeline friction resistance sensor collects real-time friction resistance data. The collected multi-dimensional dynamic operating condition data is transmitted to the central control unit in real time via industrial Ethernet, providing data support for parameter calculation of the energy-saving control module.

6. The high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines according to claim 5, characterized in that, The operating condition prediction unit integrates dynamic operating condition data and calculates the optimal liquid supply flow rate through a liquid demand prediction model, as follows: Receive dynamic operating condition data collected by the operating condition sensing module and forwarded by the central control unit; Based on the matching relationship between dynamic working condition data and preset thresholds, three key coefficients are derived: coal mining machine load coefficient, support action coefficient, and roof pressure coefficient. The optimal fluid supply flow rate is calculated using a fluid demand prediction model based on the coal mining machine load factor, support movement factor, roof pressure factor, and foundation fluid supply flow rate. The calculation formula is as follows: In the formula, To achieve the optimal liquid supply flow rate; Basic liquid supply flow rate; It is the load factor of the coal mining machine; It is the stent's action coefficient; It is the pressure coefficient of the roof slab; The calculated optimal fluid supply flow rate is transmitted to the friction resistance compensation unit and the pump group cluster coordination unit.

7. The high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines according to claim 6, characterized in that, The friction resistance compensation unit calculates the accurate compensation pressure using a dynamic resistance compensation formula, as follows: Receive real-time pipeline friction resistance data transmitted by the working condition sensing module, and the optimal fluid supply flow rate output by the working condition prediction unit. The resistance fluctuation coefficient is calculated based on the ratio of real-time friction support resistance data to the preset resistance per unit length of pipeline foundation. Obtain the actual conveying distance and the rated liquid supply pressure at the end of the working face, and calculate the compensated pressure that the pump set needs to output using the dynamic resistance compensation formula, based on the resistance fluctuation coefficient. The calculation formula is as follows: In the formula, , The rated liquid supply pressure at the end of the working face, L is the foundation resistance per unit length of pipeline. , This is the resistance fluctuation coefficient; After calculating the compensation The data is transmitted to the central control unit, and a pressure regulation reference command is simultaneously sent to the end pressure regulating valve group of the long-distance delivery module.

8. The high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines according to claim 7, characterized in that, The pump group cluster coordination unit achieves optimal load allocation among multiple pumps through a load allocation formula, as follows: It receives the optimal liquid supply flow rate output by the working condition prediction unit and the compensated pressure output by the friction resistance compensation unit, and simultaneously obtains the rated parameters and maximum transmission efficiency of each pump group in the liquid supply power module. The optimal output flow rate of each pump is calculated using a load distribution formula to ensure that the load of multiple pumps is balanced and the cluster operates in the highest efficiency range. Based on the optimal output flow of each pump, and combined with the compensated pressure, frequency conversion adjustment commands for each pump group are generated and transmitted to the central control unit.

9. A high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines according to claim 8, characterized in that, The long-distance transmission module is implemented as follows: The high-pressure emulsion output from the power supply module is transported over long distances through high-strength, high-pressure-resistant pipelines. During the transport process, the emulsion is filtered through a three-stage filtration system to ensure its cleanliness and prevent wear on hydraulic components. The end pressure regulating valve group receives the adjustment command issued by the friction resistance compensation unit, and adjusts the valve group opening in real time in combination with the actual end pressure data it collects, so as to accurately compensate the delivery pressure. The compensated emulsion is stably delivered to the hydraulic equipment at the working face to ensure that the end supply pressure is stable within the rated range and meets the working requirements of the equipment.

10. A high-efficiency, multi-stage energy-saving, long-distance intelligent liquid supply system for coal mines according to claim 9, characterized in that, The central control unit is implemented as follows: Receive all dynamic operating condition data transmitted by the operating condition sensing module and forward it to the operating condition prediction unit of the energy-saving control module; It receives the optimal liquid supply flow rate, compensated pressure, and optimal output flow rate of each pump group from the energy-saving control module, and integrates them to generate the frequency conversion adjustment command of the liquid supply power module. The variable frequency adjustment command of each pump group is sent to the liquid supply power module to control multiple pump groups to operate in coordination according to the optimal load parameters. At the same time, the pressure-related command after compensation is forwarded to the end pressure regulating valve group of the long-distance delivery module to complete the pressure compensation in a coordinated manner. The system monitors the operating status of each module in real time. When abnormal data transmission, pump failure, or deviation of liquid supply pressure / flow from the threshold is detected, an emergency response is immediately initiated to ensure stable system operation.

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