Method for judging blockage of hydraulic support back-flushing filter and electronic device

Abstract

The present application relates to the technical field of fault diagnosis, and particularly relates to a hydraulic support backwashing filter blockage judgment method and electronic equipment, at least three pressure sensors are integrated on the backwashing filter, which are respectively used for collecting the pressure P1 of the valve core inlet liquid cavity, the pressure P2 of the valve core outlet liquid cavity / filter core inlet liquid cavity and the pressure P3 of the filter core outlet liquid cavity in real time; the method comprises the following steps: synchronously acquiring real-time data of the pressures P1, P2 and P3; based on the real-time data, calculating a first characteristic pressure difference ΔP1=P1-P2 and a second characteristic pressure difference ΔP2=P2-P3; comparing the second characteristic pressure difference ΔP2 with a preset filter core blockage threshold β; if ΔP2>=β, further comparing the first characteristic pressure difference ΔP1 with a preset valve core normal pressure difference range [γ1, γ2]; if ΔP1 is in the valve core normal pressure difference range, it is determined that the filter core is blocked; if ΔP1 exceeds the valve core normal pressure difference range, it is determined that the backwashing valve core is abnormal.

Description

Technical Field

[0001] This invention relates to the field of fault diagnosis technology, and in particular to a method and electronic device for determining the blockage of a hydraulic support backflushing filter. Background Technology

[0002] Backwash filters are key components in hydraulic support systems used to purify emulsions, ensuring the cleanliness of hydraulic fluids and thus maintaining stable system operation. Their basic working principle is as follows: A filter element intercepts impurities in the working medium. When the filter element becomes clogged due to impurity accumulation, the fluid flow direction is reversed, causing the clean fluid to flow back towards the filter element, flushing away impurities adhering to the outer surface of the filter screen and discharging them through the drain port, thereby restoring the filter element's filtration capacity. A typical backwash filter usually consists of a valve body, multiple filter elements and their corresponding valve core assemblies, a pilot valve (such as a solenoid pilot valve) controlling flow path switching, and inlet, outlet, and drain ports connecting the various flow channels.

[0003] In hydraulic support systems, backwash filters are core components ensuring the cleanliness of hydraulic fluids. Their main function is to physically intercept and remove solid particulate impurities from media such as emulsions. As impurities accumulate on the filter element surface, the pressure difference across the filter element (i.e., the difference between the inlet and outlet pressures) gradually increases. This becomes the most direct and widely used technical indicator for judging the degree of filter element clogging. Therefore, automatic backwashing technology based on differential pressure monitoring has become the mainstream development direction in this field. Existing automatic backwash filters are generally equipped with a valve body, filter element, valve core for controlling flow channel switching, electromagnetic pilot valve for driving the valve core, and a sensor for monitoring the pressure difference across the filter element. Its basic operating logic includes: the control system collects data from the differential pressure sensor in real time or at regular intervals. Once the detected differential pressure value reaches or exceeds a preset fixed threshold, the filter element is considered to be clogged and needs cleaning. At this time, the controller issues a command to activate the electromagnetic pilot valve, causing the valve core to switch direction, guiding the system fluid flow in the opposite direction through the inside of the filter element, removing dirt from the outside of the filter screen, and discharging it through the drain port. Afterward, the valve core resets, and the system returns to normal filtration mode.

[0004] However, this basic backwash triggering mechanism is highly dependent on the accuracy of the preset threshold and the stability of the differential pressure signal. Its reliability can be significantly affected by complex and variable real-world conditions, such as system flow fluctuations, pressure surges, or sensor measurement errors. Furthermore, traditional backwash filters lack comprehensive perception and intelligent decision-making capabilities regarding the overall system status, making it difficult to accurately assess filter element clogging and perform timely and effective backwashing. Summary of the Invention

[0005] This invention provides a method and electronic device for judging the blockage of a hydraulic support backwash filter, which solves the problem that the existing technology relies solely on a single differential pressure signal to judge the blockage status of the filter element, and cannot distinguish between filter element blockage and backwash valve core failure, resulting in frequent misjudgments, missed judgments, or invalid backwash operations. It achieves accurate identification, fault location, and high reliability status assessment of filter element blockage and valve core abnormalities.

[0006] This invention provides a method for determining the blockage of a hydraulic support backwash filter. The backwash filter integrates at least three pressure sensors, which are used to collect the pressure P1 of the valve core inlet chamber, the pressure P2 of the valve core outlet chamber / filter core inlet chamber, and the pressure P3 of the filter core outlet chamber in real time. The method includes: synchronously acquiring real-time data of pressures P1, P2, and P3; calculating a first characteristic pressure difference ΔP1 = P1 - P2 and a second characteristic pressure difference ΔP2 = P2 - P3 based on the real-time data; comparing the second characteristic pressure difference ΔP2 with a preset filter core blockage threshold β; if ΔP2 ≥ β, further comparing the first characteristic pressure difference ΔP1 with a preset normal valve core pressure difference range [γ1, γ2]; if ΔP1 is within the normal valve core pressure difference range, the filter core is determined to be blocked; if ΔP1 exceeds the normal valve core pressure difference range, the backwash valve core is determined to be abnormal.

[0007] According to one embodiment of the present invention, if ΔP2 < β, the filter element is determined to be unobstructed and the system is normal.

[0008] According to one embodiment of the present invention, after determining that the filter element is clogged, the method further includes generating a corresponding backwashing control command based on the degree to which ΔP2 exceeds the filter element clogging threshold β.

[0009] According to one embodiment of the present invention, after determining that there is an abnormality in the backflushing valve core, the method further includes generating a valve core maintenance alarm and sending it to the monitoring center.

[0010] According to one embodiment of the present invention, the instantaneous flow rate Q flowing through the backwash filter is calculated in real time based on the first characteristic pressure difference ΔP1 and the flow-pressure difference characteristic curve of the backwash filter valve core, according to a pre-calibrated curve.

[0011] According to one embodiment of the present invention, the method further includes performing system energy efficiency analysis or leakage assessment based on the instantaneous flow rate Q.

[0012] According to one embodiment of the present invention, after each execution of the blockage judgment method, a comprehensive test report is generated. The comprehensive test report includes the final diagnostic conclusion, the original pressure data P1 / P2 / P3, the calculated characteristic pressure difference ΔP1 / ΔP2, the instantaneous flow rate Q, and the corresponding maintenance suggestions or control instructions.

[0013] According to one embodiment of the present invention, the normal differential pressure range [γ1, γ2] of the valve core is determined based on the normal hydraulic model of the backwash filter before leaving the factory or after maintenance.

[0014] According to one embodiment of the present invention, the pressure sensor is integrated and installed on the body of the backwash filter, and is directly connected to the valve core inlet chamber, the valve core outlet chamber and the filter core outlet chamber, respectively.

[0015] The present invention also provides an electronic device, including a memory, a processor, and a computer program stored in the memory and running on the processor, wherein the processor executes the computer program to implement the hydraulic support backwash filter clogging judgment method of the above embodiments.

[0016] The hydraulic support backwash filter clogging judgment method and electronic device provided by this invention integrates at least three pressure sensors on the backwash filter body to collect the pressure P1 of the valve core inlet chamber, the pressure P2 of the valve core outlet chamber (i.e., the filter core inlet chamber), and the pressure P3 of the filter core outlet chamber in real time, and simultaneously calculates two key characteristic pressure differences: ΔP1=P1-P2 (reflecting the valve core flow resistance state) and ΔP2=P2-P3 (reflecting the filter core contamination degree). First, ΔP2 is compared with a preset filter core clogging threshold β. If ΔP2≥β, it indicates that there may be clogging. At this time, it is not directly judged as filter core clogging, but further checked whether ΔP1 is within the pressure difference range [γ1,γ2] of normal valve core operation. If ΔP1 is within this range, it means that the valve core flow is normal, and the pressure difference increase is indeed caused by filter core clogging, thus accurately judging "filter core clogging". If ΔP1 exceeds this range, it means that the valve core itself has abnormalities such as jamming, wear, or sealing failure, resulting in abnormal flow resistance. At this time, it is judged as "backwash valve core failure" rather than filter core problem. This method effectively decouples the state influence of filter element and valve element through dual differential pressure coupling analysis and hierarchical diagnostic logic, significantly improving the accuracy of blockage judgment and the system's self-diagnostic capability, and avoiding ineffective backwashing, equipment damage or production interruption caused by misjudgment. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a flowchart illustrating the method for determining the blockage of the backwash filter of a hydraulic support provided by the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0020] This invention proposes a multi-dimensional signal fusion method for determining the blockage of a hydraulic support backwash filter. To implement this method, improvements to the existing hardware structure are required: a differential pressure detection device containing at least three independent pressure sensing units can be integrated into the backwash filter body. These three sensors must be precisely positioned at key locations with different hydraulic functions. Specifically, the first measuring point is located in the inlet chamber of the backwash valve core to acquire the upstream system pressure P1; the second measuring point is located in the outlet chamber of the valve core (i.e., the filter core's inlet chamber) to acquire the intermediate pressure P2; and the third measuring point is located in the filter core's outlet chamber to monitor the outlet pressure P3 of the cleaning fluid flow. By simultaneously acquiring the three pressure signals P1, P2, and P3, a hardware foundation is laid for subsequently constructing a multi-feature differential pressure model and achieving accurate identification of filter core blockage and valve core anomalies.

[0021] Specifically, based on the hydraulic support backwash filter clogging judgment method of the present invention, the backwash filter is integrated with at least three pressure sensors, which are used to collect the pressure P1 of the valve core inlet chamber, the pressure P2 of the valve core outlet chamber / filter element inlet chamber and the pressure P3 of the filter element outlet chamber in real time. Figure 1 This is a flowchart illustrating the method for determining the blockage of the backwash filter in a hydraulic support provided by the present invention. Figure 1 As shown, the method includes the following: Step 110: Synchronously acquire real-time data of pressures P1, P2, and P3. The controller synchronously reads the output values ​​of the three pressure sensors installed on the backwash filter body within the same sampling period (usually milliseconds) through a high-precision analog input module or digital communication interface: P1 represents the inlet pressure of the upstream system entering the valve core after pilot control, P2 reflects the intermediate pressure at the valve core outlet, which is also the filter element inlet, and P3 is the outlet pressure of the clean emulsion after passing through the filter element.

[0022] Step 120: Based on real-time data, calculate the first characteristic pressure difference ΔP1 = P1 - P2 and the second characteristic pressure difference ΔP2 = P2 - P3. After acquiring P1, P2, and P3, the controller immediately calculates the two characteristic pressure differences with different physical meanings in parallel: ΔP1 represents the resistance loss of the internal flow channel of the backwash valve core, directly reflecting whether the valve core is opened normally, whether there is jamming or sealing failure; ΔP2 represents the filtration resistance of the filter element body, which is the core indicator for judging the degree of filter element contamination or blockage.

[0023] Step 130: Compare the second characteristic pressure difference ΔP2 with the preset filter element clogging threshold β to preliminarily determine whether the filter element may be clogged. Wherein: Step 131: If ΔP2 ≥ β, then the first characteristic pressure difference ΔP1 is further compared with the preset normal pressure difference range of the valve core [γ1, γ2]. Specifically, when ΔP2 exceeds the clogging threshold β (e.g., 1.0 MPa), it indicates an abnormal total system pressure drop, but this cannot be directly attributed to filter element clogging. The system then initiates a cross-validation mechanism to check whether ΔP1 falls within the normal operating range [γ1, γ2] (e.g., 0.5~1.2 MPa) pre-calibrated according to the hydraulic characteristics of this model of backwash valve core. This step aims to eliminate interference from "false high pressure difference" caused by valve core failure and ensure the accuracy of the diagnostic conclusion.

[0024] Step 132: If ΔP1 is within the normal differential pressure range of the valve core, the filter element is determined to be clogged. When ΔP2 exceeds the standard and ΔP1 is within the normal range, it indicates that the valve core flow is good and the test path is reliable. In this case, the high differential pressure is entirely caused by the filter element itself being clogged. Based on this, the system generates the conclusion of "filter element clogged" and can trigger subsequent intelligent backwash control commands to execute precise and effective cleaning operations.

[0025] Step 133: If ΔP1 exceeds the normal differential pressure range of the valve core, the backflushing valve core is deemed to be abnormal. Specifically, if ΔP2 exceeds the limit while ΔP1 also significantly deviates from the normal range (e.g., ΔP1 = 2.0 MPa > γ2), it indicates that the backflushing valve core may not be fully open, has internal wear, or is blocked by foreign objects, resulting in an abnormally increased flow resistance. In this case, the system determines it as "valve core abnormality" or "combined fault," and prioritizes issuing a maintenance alarm rather than performing backflushing to avoid ineffective operation or even aggravating equipment damage.

[0026] In practical applications, based on the aforementioned method for judging the blockage of the hydraulic support backwash filter, highly reliable status perception and intelligent operation and maintenance can be achieved in the fully mechanized mining face. For example, during the operation of an 8.8-meter ultra-high mining face, the system automatically initiates blockage diagnosis periodically: it detects P1=20MPa, P2=18MPa, and P3=16MPa at one time, and calculates ΔP1=2.0MPa and ΔP2=2.0MPa. Since ΔP2 > β (1.0 MPa) and ΔP1 far exceeds the normal range of [0.5, 1.2] MPa, the system accurately identified it as "valve core jamming" and sent a "valve core failure, please repair" alarm to the roadway monitoring center, avoiding blind backflushing. In another test, P1=20 MPa, P2=19 MPa, P3=17 MPa, ΔP1=1.0 MPa (normal), and ΔP2=2.0 MPa (exceeding the standard), the system reliably determined it as "severe filter blockage" and linked the intelligent control module to perform a backflushing operation with optimized duration. In addition, the system can also use the known ΔP1 and valve core flow-pressure difference characteristic curve to calculate the instantaneous flow rate Q in real time, providing high-value data for emulsion system energy efficiency analysis and leakage monitoring. After each diagnosis, the system automatically generates a comprehensive test report including the original pressure, characteristic pressure difference, flow estimation, diagnostic conclusions, and maintenance suggestions, fully supporting predictive maintenance and digital management.

[0027] Furthermore, according to the present invention, a method for determining the blockage of a hydraulic support backflushing filter further includes: Step 134: If ΔP2 < β, the filter element is considered unobstructed, and the system is normal. Specifically, when the calculated second characteristic pressure difference ΔP2 (i.e., the pressure drop across the filter element) is lower than the preset filter element clogging threshold β, it indicates that the current filter element flow resistance is within the normal range, and the accumulation of impurities has not yet reached a level that affects system performance. At this time, regardless of the specific value of the first characteristic pressure difference ΔP1 (as long as the independent valve core fault diagnosis logic is not triggered), the system can directly conclude that the filter element is in good condition and no intervention is needed, and end the current diagnostic process or enter the low-frequency monitoring mode. This judgment mechanism effectively avoids the accidental initiation of backwashing operation when the filter element is clean, thereby saving emulsion resources, reducing unnecessary wear of solenoid valves, and improving the overall operating efficiency of the system.

[0028] Furthermore, according to the hydraulic support backwash filter clogging judgment method of the present invention, after determining that the filter element is clogged, the method further includes generating a corresponding backwash control command based on the degree to which ΔP2 exceeds the filter element clogging threshold β. Specifically, after confirming that the filter element is clogged (i.e., ΔP2≥β and ΔP1∈[γ1,γ2]), the system does not perform backwashing for a fixed duration, but dynamically generates a refined backwash control command based on the over-limit amplitude (ΔP2-β). For example, the over-limit degree can be divided into three levels: mild (0~0.5MPa), moderate (0.5~1.0MPa), and severe (>1.0MPa), corresponding to three backwash durations: short (e.g., 5 seconds), medium (e.g., 8 seconds), and long (e.g., 12 seconds), respectively; or the optimal flushing time can be calculated in real time using a preset linear / nonlinear function t=f(ΔP2-β). This scheme ensures that mild clogging requires short flushing and severe clogging requires long flushing, guaranteeing thorough cleaning while avoiding energy and media waste caused by over-flushing.

[0029] Furthermore, according to the hydraulic support backwash filter clogging judgment method of the present invention, after determining that there is an abnormality in the backwash valve core, the method further includes generating a valve core maintenance alarm and sending it to the monitoring center. Specifically, when the system diagnoses that ΔP1 exceeds the normal differential pressure range of the valve core [γ1, γ2] (especially when ΔP2 also exceeds the limit), it is determined that the backwash valve core has mechanical or hydraulic faults such as jamming, sealing failure, poor pilot valve response, or internal wear. At this time, the controller will immediately generate a structured "valve core abnormality" maintenance alarm, the content of which preferably includes the target support number, abnormality type, three original pressure values ​​(P1 / P2 / P3), calculated differential pressure (ΔP1 / ΔP2), occurrence time, and suggested handling measures (such as "check valve core opening status" or "replace pilot component"), and push it to the roadway control center or ground monitoring platform in real time through the working face communication network (such as CAN bus or industrial Ethernet). This alarm not only alerts maintenance personnel to intervene in a timely manner, but also automatically links to the equipment ledger and triggers preventive maintenance work orders. It prevents long-term poor fluid supply, misjudgment of filter elements, or complete failure of backwashing function caused by valve core failure, thus significantly improving the reliability and maintainability of the hydraulic system.

[0030] According to the present invention, a method for determining the blockage of a hydraulic support backwash filter further includes using a first characteristic pressure difference ΔP1 to calculate the instantaneous flow rate Q flowing through the backwash filter in real time based on a pre-calibrated flow-pressure difference characteristic curve of the backwash filter valve core. Given a fixed structure and diameter of the backwash valve core, the hydraulic characteristics of its internal flow channels are repeatable and calibrable. During equipment manufacturing or maintenance, the flow-pressure difference mapping relationship of the valve core in its normal open state (i.e., Q=f(ΔP1)) can be established through experiments or CFD simulation, forming a dedicated flow-pressure difference characteristic curve and storing it in the controller. During actual operation, after completing the calculation of ΔP1=P1-P2, the system can substitute the measured pressure difference value into the pre-stored characteristic function to deduce the instantaneous volumetric flow rate Q of the emulsion currently flowing through the filter in real time. Since this flow rate is derived from the pressure difference directly measured by the valve core body, it has higher accuracy and response speed compared to the traditional method of indirect estimation through column action speed or pump station output, and is not affected by the downstream actuator status.

[0031] Furthermore, according to the method for determining the blockage of a hydraulic support backflushing filter based on the present invention, the method also includes performing system energy efficiency analysis or leakage assessment based on the instantaneous flow rate Q. On the one hand, when the support performs standard actions (such as column raising and support moving), if Q is significantly lower than the historical benchmark value or the theoretical requirement value, it may indicate that there is throttling in the fluid supply line, insufficient pump output, or increased internal leakage in the system, thus supporting the energy efficiency degradation analysis. On the other hand, when the support is in a static pressure-holding state, if Q still remains at a non-zero level (exceeding the reasonable leakage threshold), it can be determined that there is abnormal internal / external leakage in the system, such as failure of the hydraulic control check valve seal, leakage of the hose joint, or damage to the column seal. By continuously monitoring the changing trend of Q and combining it with contextual information such as pressure and action commands, the system can achieve dynamic assessment of the sealing performance and energy utilization efficiency of the hydraulic circuit, providing data support for predictive maintenance, energy-saving optimization, and early warning of faults.

[0032] According to a method for determining the blockage of a hydraulic support backwash filter based on the present invention, a comprehensive test report is generated after each execution of the blockage determination method. The comprehensive test report includes the final diagnostic conclusion, the original pressure data P1 / P2 / P3, the calculated characteristic pressure differences ΔP1 / ΔP2, the instantaneous flow rate Q, and the corresponding maintenance suggestions or control commands. Specifically, after completing a complete blockage diagnosis process, the controller preferably automatically encapsulates all the information from this test to form a structured comprehensive test report. This report can not only include the core diagnostic results (such as "filter blockage", "valve core abnormality" or "system normal"), but also fully record the three original pressure values ​​(P1, P2, P3), the two characteristic pressure differences (ΔP1, ΔP2) calculated from them, and the instantaneous flow rate Q derived from ΔP1. Based on the diagnostic conclusion, it intelligently matches the corresponding subsequent action suggestions, such as "execute 8-second backwash", "prohibit backwashing, please inspect the valve core", or "continue monitoring". The report can be uploaded to the working face centralized control system or cloud operation and maintenance platform via the communication interface. It is used for equipment health record establishment, fault trend analysis, automatic generation of maintenance work orders and remote expert diagnosis, realizing a data closed loop from single judgment to the whole life cycle.

[0033] According to the present invention, a method for determining the blockage of a hydraulic support backwash filter, the normal differential pressure range [γ1, γ2] of the valve core is determined based on the normal hydraulic model of the backwash filter before leaving the factory or after maintenance. After the backwash filter completes manufacturing and assembly or major overhaul and replacement of key components (such as the valve core and seals), its hydraulic performance is calibrated on a standard test bench. Specifically, under rated flow and operating pressure, the stable differential pressure between P1 and P2 in the fully open state of the valve core is measured, and combined with test data under different flow conditions, a differential pressure fluctuation range for this specific individual under normal operating conditions is established. Considering manufacturing tolerances, changes in medium viscosity, and slight wear, this range is set as a closed range [γ1, γ2] with a certain tolerance (e.g., 0.5MPa≤ΔP1≤1.2MPa), and can be written into its electronic identity file or controller configuration parameters as the health baseline of the filter. In actual operation, the system uses this personalized threshold as a benchmark to verify the valve core status, improving the adaptability and accuracy of fault identification.

[0034] According to the present invention, a method for determining the blockage of a hydraulic support backwash filter, to ensure the real-time performance, accuracy, and anti-interference capability of the pressure signal, the pressure sensor is preferably integrated and installed on the body of the backwash filter, and is directly connected to the valve core inlet chamber, valve core outlet chamber, and filter element outlet chamber, respectively. The three high-precision pressure sensors are preferably directly integrated into the backwash filter valve body in an embedded manner or rigidly connected through short straight pressure measurement holes, forming a dead-zone-free, low-delay fluid path with the valve core inlet chamber (upstream side), valve core outlet chamber (i.e., filter element inlet chamber, intermediate chamber), and filter element outlet chamber (downstream side), respectively. This integrated design avoids the risks of signal lag, pulsation attenuation, joint leakage, or blockage caused by traditional external pressure measurement pipelines, enabling P1, P2, and P3 to accurately reflect the instantaneous pressure status of each key node.

[0035] According to a preferred embodiment of the present invention, a method for determining the blockage of a hydraulic support backwash filter is provided. This method integrates three high-precision pressure sensors on the backwash filter body to collect real-time pressure data of the valve core inlet chamber (P1), valve core outlet chamber (i.e., filter element inlet chamber) (P2), and filter element outlet chamber (P3), respectively. This constructs an intelligent diagnostic mechanism based on multi-point synchronous sensing and dual-pressure differential cross-verification. In each test cycle, the controller synchronously acquires the three pressure signals and calculates two characteristic pressure differences: ΔP1 = P1 - P2 reflects the flow state of the backwash valve core itself, serving as an environmental verification indicator for determining the reliability of the test path; ΔP2 = P2 - P3 directly characterizes the degree of filter element contamination, serving as the core clogging criterion.

[0036] The system first compares ΔP2 with the preset filter clogging threshold β. If ΔP2 is below the threshold, the filter is considered clear and the system is operating normally. If ΔP2 reaches or exceeds the threshold, backwashing is not immediately triggered. Instead, the system further verifies whether ΔP1 is within the normal differential pressure range [γ1, γ2] of the valve core, as determined by the equipment's factory calibration or maintenance. Only when ΔP1 falls within this reasonable range is the test environment confirmed to be reliable, and the filter is ultimately determined to be clogged. Simultaneously, a matching backwashing duration command is dynamically generated based on the degree to which ΔP2 exceeds the threshold. If ΔP1 is abnormally high or low, it indicates that the backwash valve core itself has faults such as jamming, wear, or incomplete opening. In this case, the system determines that the valve core is abnormal and generates a maintenance alarm containing specific parameters and suggestions, which is pushed to the monitoring center to effectively avoid false flushing and invalid operations caused by valve core problems.

[0037] This method not only achieves accurate identification of blockage states but also possesses preliminary fault source localization capabilities. By using the valve core pressure difference ΔP1 as an intrinsic verification dimension, the system can accurately distinguish whether the root cause of the problem originates from the filter element or the valve core under complex operating conditions with increased total pressure drop, significantly improving the practicality of diagnosis and maintenance efficiency. Simultaneously, the synchronous acquisition and logical cross-verification of dual pressure difference signals form a natural anti-interference mechanism, making it difficult for occasional fluctuations in a single signal to cause misjudgments, thus enhancing system robustness. Furthermore, using the calibrated valve core flow-pressure difference characteristic curve, the system can calculate the instantaneous flow rate Q flowing through the filter in real time based on the high-fidelity ΔP1. This data comes directly from the measured flow channel, is unaffected by downstream actuator leakage or multi-channel distribution, and its accuracy is far higher than traditional indirect estimation methods, providing a reliable basis for advanced functions such as energy efficiency analysis and leak monitoring.

[0038] After each diagnosis, the system automatically generates a structured comprehensive test report, including raw pressure data, calculated differential pressure, instantaneous flow rate, diagnostic conclusions, and corresponding control or maintenance recommendations. This report can be uploaded to the centralized control platform via a communication network, supporting the construction of equipment health records and predictive maintenance. Thus, this method transforms the backwash filter from a single-function component into a key sensing node for the intelligent operation and maintenance of hydraulic systems, significantly expanding its technological value and application potential.

[0039] This invention also provides an electronic device, which is described below. The electronic device described below can be referred to in conjunction with the hydraulic support backwash filter clogging judgment method described above. Specifically, the electronic device can be a main controller of the hydraulic support electro-hydraulic control system, an edge computing gateway for the fully mechanized mining face, a dedicated status monitoring module, or an embedded intelligent diagnostic terminal, etc. The electronic device may include a memory, a processor, and a computer program stored in the memory and running on the processor. When the processor executes the computer program, it implements the hydraulic support backwash filter clogging judgment method described above. Specifically, the processor receives signals P1, P2, and P3 from three pressure sensors integrated on the backwash filter body in real time through a communication interface. It loads and runs a diagnostic program in the memory, including core algorithms such as synchronous sampling, dual-feature differential pressure calculation, threshold comparison, cross-validation logic, flow conversion, and report generation, thereby accurately identifying filter element clogging and valve core abnormalities. Simultaneously, the electronic device can automatically output backwash control commands or generate structured maintenance alarms based on the diagnostic results, and upload a comprehensive test report to the monitoring center via an industrial communication bus, realizing a complete closed loop from data acquisition and intelligent analysis to decision execution.

[0040] Furthermore, the logical instructions in the aforementioned memory can be implemented as software functional units and sold or used as independent products, and can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory, random access memory, magnetic disks, or optical disks.

[0041] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for determining the blockage of a hydraulic support backflushing filter, characterized in that, The backwash filter integrates at least three pressure sensors, which are used to collect the pressure P1 of the valve core inlet chamber, the pressure P2 of the valve core outlet chamber / filter element inlet chamber, and the pressure P3 of the filter element outlet chamber in real time; the method includes: Simultaneously acquire real-time data of pressures P1, P2, and P3; Based on the real-time data, calculate the first characteristic pressure difference ΔP1=P1-P2 and the second characteristic pressure difference ΔP2=P2-P3; The second characteristic pressure difference ΔP2 is compared with the preset filter element clogging threshold β; If ΔP2≥β, then the first characteristic pressure difference ΔP1 is compared with the preset normal pressure difference range of the valve core [γ1,γ2]. If ΔP1 is within the normal differential pressure range of the valve core, the filter element is determined to be clogged; if ΔP1 exceeds the normal differential pressure range of the valve core, the backwash valve core is determined to be abnormal. After determining that the filter element is clogged, the process also includes generating a corresponding backwashing control command based on the degree to which ΔP2 exceeds the filter element clogging threshold β. The method further includes using the first characteristic pressure difference ΔP1 to calculate the instantaneous flow rate Q flowing through the backwash filter in real time based on the pre-calibrated flow-pressure difference characteristic curve of the backwash filter valve core; The method also includes performing system energy efficiency analysis or leakage assessment based on the instantaneous flow rate Q; After each execution of the blockage judgment method, a comprehensive test report is generated. The comprehensive test report includes the final diagnostic conclusion, the original pressure data P1 / P2 / P3, the calculated characteristic pressure difference ΔP1 / ΔP2, the instantaneous flow rate Q, and the corresponding maintenance suggestions or control instructions.

2. The method for determining clogging of the hydraulic support backflushing filter according to claim 1, characterized in that, If ΔP2 < β, then the filter element is considered unobstructed and the system is normal.

3. The method for determining clogging of the hydraulic support backflushing filter according to claim 1, characterized in that, After determining that there is an abnormality in the backflushing valve core, the process also includes generating a valve core maintenance alarm and sending it to the monitoring center.

4. The method for determining clogging of the backwash filter of a hydraulic support according to any one of claims 1 to 3, characterized in that, The normal differential pressure range [γ1, γ2] of the valve core is determined based on the normal hydraulic model of the backwash filter before leaving the factory or after maintenance.

5. The method for determining the blockage of the backwash filter of a hydraulic support according to any one of claims 1 to 3, characterized in that, The pressure sensor is integrated and installed on the body of the backwash filter, and is directly connected to the valve core inlet chamber, valve core outlet chamber and filter core outlet chamber respectively.

6. An electronic device comprising a memory, a processor, and a computer program stored in the memory and running on the processor, characterized in that, When the processor executes the computer program, it implements the method for determining the blockage of the hydraulic support backwash filter as described in any one of claims 1 to 5.

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