Self-adaptive foam dust removal regulation and control system based on cutting power feedback of roadheader

Abstract

The invention provides a self-adaptive foam dust removal regulation and control system based on cutting power feedback of a fully-mechanized excavating machine, which belongs to the technical field of dust removal of an underground coal mine fully-mechanized excavating face and comprises a fully-mechanized excavating machine working condition sensing unit, a main control unit, a foam generation execution unit, a multi-parameter feedback unit and a dust removal effect verification unit, wherein the fully-mechanized coal winning machine working condition sensing unit is used for acquiring operation power data and cutting action state data of a cutting mechanism of the fully-mechanized coal winning machine in real time and transmitting the acquired data to the main control unit. According to the invention, the fully-mechanized coal winning machine working condition sensing unit, the main control unit, the foam generation execution unit, the multi-parameter feedback unit and the dust removal effect verification unit are arranged, dust production feed-forward pre-judgment is realized through cutting power and action data, and foam parameter self-adaptive matching is completed in combination with double-closed-loop regulation and control. According to the invention, dust source inhibition of fully-mechanized excavation operation can be realized, the regulation and control precision and working condition adaptability of a dust removal system are improved, the operation cost is reduced, and the safety of underground fully-mechanized excavation operation and the quality of an operation environment are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of dust removal technology in underground coal mine tunneling faces, specifically to an adaptive foam dust removal control system based on the cutting power feedback of the tunneling machine. Background Technology

[0002] Underground tunneling operations are a crucial part of the coal production process. During the cutting process of coal and rock, the tunneling machine continuously generates a large amount of dust. This dust includes both general dust and respirable dust, which not only pose a long-term threat to the health of underground workers but also create a dust explosion hazard when it accumulates in the working area. Therefore, dust control is an essential safety measure that must be implemented in tunneling operations.

[0003] Currently, most foam dust suppression systems used in underground roadway construction face operations operate with fixed parameters. After system startup, parameters such as foam output flow rate, foaming liquid concentration, and foaming ratio remain constant, failing to adapt to changes in working conditions during roadway operations. When the roadway machine cuts hard rock or significantly adjusts its cutting action, resulting in a substantial increase in dust generation, the fixed output foam cannot effectively suppress dust, leading to excessive dust concentration at the working face. Conversely, when the roadway machine cuts soft coal or travels unloaded, resulting in a significant decrease in dust generation, the fixed output foam leads to ineffective consumption of water resources and foaming agent, increasing operating costs.

[0004] Some foam dust suppression systems with controllability rely solely on data from dust concentration sensors for parameter adjustments, resulting in significant lag. Dust concentration sensors can only detect dust that has already dispersed. The system can only adjust foam output parameters after dust has been generated, dispersed, and detected by the sensor. This prevents simultaneous suppression at the dust source, especially in scenarios with sudden changes in roadheader cutting conditions, where large amounts of dust have already spread across the entire working face before the system completes parameter adjustments, thus failing to achieve effective dust control.

[0005] Most existing dust removal systems employ open-loop or single closed-loop control architectures, focusing only on the final dust concentration detection results and neglecting the actual operational status of the entire foam generation process. After issuing control commands, the system cannot obtain real-time data on execution aspects such as water supply pressure, foaming liquid ratio, compressed air supply, and actual foam output parameters. This frequently leads to discrepancies between control commands and actual foam output parameters, compromising control accuracy. Furthermore, existing systems are completely disconnected from the operating conditions of the roadheader itself, failing to link the roadheader's cutting operation status with dust removal control. They cannot predict changes in dust generation based on the cutting operation status, and can only passively respond to already generated dust. Under the complex and variable coal and rock conditions and operational scenarios underground, the dust removal effect exhibits poor stability.

[0006] In addition, most existing dust removal systems lack online self-optimization capabilities. The preset control parameters and mapping models cannot be automatically adjusted according to changes in underground coal and rock conditions, requiring operators to manually calibrate and modify them periodically, resulting in high maintenance costs. At the same time, the fault protection capabilities of existing systems are insufficient. When a certain acquisition module or execution component in the system malfunctions, the entire dust removal system is prone to shutting down directly, leading to uncontrolled dust concentration at the working face and posing safety hazards to underground operations.

[0007] To address this, an adaptive foam dust control system based on the cutting power feedback of a roadheader is proposed. Summary of the Invention

[0008] The present invention aims to solve the problems mentioned in the background art by providing an adaptive foam dust control system based on the cutting power feedback of a roadheader.

[0009] The specific technical solution is as follows: An adaptive foam dust control system based on roadheader cutting power feedback includes a roadheader operating condition sensing unit, a main control unit, a foam generation execution unit, a multi-parameter feedback unit, and a dust removal effect verification unit, wherein: The signal acquisition end of the roadheader condition sensing unit is connected to the cutting drive module and the cutting action execution mechanism of the roadheader. The signal output end of the roadheader condition sensing unit is connected to the first signal input end of the main control unit. It is used to collect the operating power data and cutting action status data of the roadheader cutting mechanism in real time and transmit the collected data to the main control unit. The second signal input terminal of the main control unit is connected to the signal output terminal of the multi-parameter feedback unit, the third signal input terminal of the main control unit is connected to the signal output terminal of the dust removal effect verification unit, and the signal output terminal of the main control unit is connected to the control terminal of the foam generation execution unit. It is used to receive data transmitted by the roadheader working condition sensing unit, the multi-parameter feedback unit and the dust removal effect verification unit, generate foam control benchmark instructions based on the pre-stored mapping model of cutting power and dust generation, and perform closed-loop correction of the foam control benchmark instructions according to the feedback data of the multi-parameter feedback unit and the dust removal effect verification unit, and output the final foam control instructions to the foam generation execution unit. The installation end of the foam generating execution unit is fixed to the front end of the cutting mechanism of the roadheader. The medium input end of the foam generating execution unit is connected to a water supply pipe and a foaming agent storage container. It is used to receive foam control instructions output by the main control unit, adjust its own operating parameters, and output dust removal foam with corresponding parameters to the dust-generating area of ​​the cutting mechanism of the roadheader. The signal acquisition terminal of the multi-parameter feedback unit is set on the medium delivery pipeline and foaming actuator of the foam generating execution unit, and is used to collect the real-time operating parameters of the foam generating execution unit and feed the collected parameters back to the main control unit. The signal acquisition terminals of the dust removal effect verification unit are respectively set on the downwind side of the driver's operating area and the cutting dust generation area of ​​the roadheader, and are used to collect the total dust concentration and respirable dust concentration data of the tunneling face in real time, and feed back the collected dust concentration data to the main control unit.

[0010] As a preferred embodiment of the present invention, the roadheader condition sensing unit includes a cutting power acquisition module, a cutting action acquisition module, and a data preprocessing module; The signal acquisition terminal of the cutting power acquisition module is electrically connected to the drive motor of the cutting mechanism of the roadheader, and is used to acquire the three-phase voltage and three-phase current data of the cutting drive motor in real time, and calculate the real-time cutting operation power. The signal acquisition terminal of the cutting action acquisition module is connected to the displacement sensors of the feed cylinder, slewing cylinder and lifting cylinder of the cutting mechanism of the roadheader, and is used to acquire the feed speed, slewing angle and lifting height data of the cutting mechanism to obtain the cutting action status data. The signal input terminal of the data preprocessing module is connected to the signal output terminals of the cutting power acquisition module and the cutting action acquisition module, respectively. The signal output terminal of the data preprocessing module is connected to the first signal input terminal of the main control unit. It is used to filter, reduce noise and normalize the acquired power data and action status data before transmitting them to the main control unit.

[0011] As a preferred embodiment of the present invention, the main control unit has a built-in model storage module, a feedforward control module, a closed-loop correction module and an instruction output module. The model storage module is used to store the pre-calibrated mapping model between cutting power and dust generation, as well as a benchmark library of foam operating parameters that match the dust generation. The signal input terminal of the feedforward control module is connected to the output terminal of the model storage module and the working condition sensing unit of the roadheader. It is used to call the mapping model to calculate the real-time predicted dust generation based on the received real-time cutting power data and cutting action status data, match the corresponding foam operation parameter benchmark value, and generate foam control benchmark instructions. The signal input terminal of the closed-loop correction module is connected to the output terminals of the feedforward control module, the multi-parameter feedback unit, and the dust removal effect verification unit. It is used to track and correct the foam control benchmark command based on the real-time operating parameter data of the multi-parameter feedback unit, and at the same time to iteratively optimize the foam operating parameter benchmark library based on the dust concentration data of the dust removal effect verification unit to generate the final foam control command. The signal input terminal of the instruction output module is connected to the output terminal of the closed-loop correction module, and the signal output terminal of the instruction output module is connected to the control terminal of the foam generation execution unit, which is used to convert the final foam control instruction into a drive signal and output it to the foam generation execution unit.

[0012] As a preferred embodiment of the present invention, the foam generation execution unit includes a water supply control module, a foaming agent proportioning module, a gas-liquid mixing foaming module, and a foam spraying module; The water supply control module is connected to an external water supply pipe at its inlet end, and the control end of the water supply control module is connected to the signal output end of the main control unit for adjusting the water supply flow and water supply pressure according to the foam control command. The inlet of the foaming agent proportioning module is connected to the outlet of the water supply control module and the foaming agent storage container, respectively. The control terminal of the foaming agent proportioning module is connected to the signal output terminal of the main control unit, which is used to adjust the addition ratio of the foaming agent according to the foam control command and output foaming liquid of the set concentration. The inlet end of the gas-liquid mixing foaming module is connected to the outlet end of the foaming agent proportioning module. The air inlet end of the gas-liquid mixing foaming module is connected to a compressed air pipeline. The control end of the gas-liquid mixing foaming module is connected to the signal output end of the main control unit. It is used to adjust the air inlet pressure and air inlet flow according to the foam control command, and mix the foaming liquid with the compressed air to generate dust removal foam with the corresponding foaming ratio. The foam injection module has its inlet end connected to the outlet end of the gas-liquid mixing foaming module. The injection nozzle of the foam injection module faces the cutting head of the roadheader's cutting mechanism and the dust-generating area, and is used to uniformly spray the dust removal foam to the dust source.

[0013] As a preferred embodiment of the present invention, the multi-parameter feedback unit includes a water supply parameter acquisition module, a foaming liquid parameter acquisition module, a compressed air parameter acquisition module, and a foam parameter acquisition module; The water supply parameter acquisition module is installed on the inlet and outlet pipelines of the water supply control module to collect real-time flow and pressure data of the water supply. The foaming liquid parameter acquisition module is installed on the outlet pipeline of the foaming agent proportioning module and is used to collect real-time concentration and flow rate data of the foaming liquid. The compressed air parameter acquisition module is installed on the air inlet pipe of the gas-liquid mixing foaming module and is used to collect real-time flow and pressure data of compressed air. The foam parameter acquisition module is installed on the outlet pipe of the gas-liquid mixing foaming module and is used to collect the real-time foaming ratio and real-time flow data of the generated foam. The signal output terminals of the water supply parameter acquisition module, foaming liquid parameter acquisition module, compressed air parameter acquisition module, and foam parameter acquisition module are all connected to the second signal input terminal of the main control unit.

[0014] As a preferred embodiment of the present invention, the dust removal effect verification unit includes a first dust collection module, a second dust collection module, and a data calibration module; The first dust collection module is fixedly installed at the operator's cab of the roadheader to collect real-time data on total dust concentration and respirable dust concentration in the operator's operating area. The second dust collection module is fixedly installed on the downwind side of the cutting mechanism of the roadheader, and the horizontal distance between it and the cutting head is kept within a preset range. It is used to collect data on the total dust concentration and respirable dust concentration after the dust is diffused in the cutting dust generation area in real time. The signal input terminal of the data calibration module is connected to the signal output terminals of the first dust collection module and the second dust collection module, respectively. The signal output terminal of the data calibration module is connected to the third signal input terminal of the main control unit. It is used to synchronously calibrate and remove outliers from the two collected dust concentration data before transmitting them to the main control unit.

[0015] As a preferred embodiment of the present invention, the closed-loop correction module has a built-in parameter iteration optimization submodule. The parameter iteration optimization submodule is used to compare the real-time dust concentration data collected by the dust removal effect verification unit with the preset dust concentration threshold. When the real-time dust concentration data exceeds the preset threshold, the flow rate and foaming ratio parameters of the foam output are adjusted upward by a preset step size. At the same time, the adjusted parameters and the corresponding cutting power and dust generation data are stored in the model storage module to perform online iterative optimization on the cutting power and dust generation mapping model and the foam operation parameter benchmark library.

[0016] As a preferred embodiment of the present invention, the foam spraying module includes an annular spraying frame and multiple sets of adjustable spray nozzles. The annular spraying frame is coaxially fixed to the front end of the cutting arm of the roadheader cutting mechanism and arranged around the rear end of the cutting head. The multiple sets of adjustable spray nozzles are evenly arranged around the circumference of the annular spraying frame. The spraying angle of each set of adjustable spray nozzles can be adjusted independently. The liquid inlet end of all adjustable spray nozzles is connected to the foam outlet end of the gas-liquid mixing foaming module.

[0017] As a preferred embodiment of the present invention, the signal input terminal of the main control unit is also connected to the overall control system of the roadheader, and is used to receive the overall start / stop signal of the roadheader and the start / stop signal of the cutting mechanism. When the start signal of the cutting mechanism is received, the main control unit starts the foam generating execution unit for a preset time. When the stop signal of the cutting mechanism is received, the main control unit shuts down the foam generating execution unit after a preset time.

[0018] As a preferred embodiment of the present invention, the main control unit also has a built-in fault diagnosis and safety protection module. The signal input terminal of the fault diagnosis and safety protection module is connected to the output terminals of the tunnel boring machine working condition sensing unit, the multi-parameter feedback unit, and the dust removal effect verification unit, respectively, for real-time monitoring of the operating status of each unit. When any abnormal data or fault is detected in any unit, a fault alarm signal is generated, and the system switches to a preset safe operation mode to ensure the stable operation of the basic dust removal function of the dust removal system.

[0019] The present invention has the following beneficial effects: This system achieves adaptive control of foam dust removal in tunneling faces by combining forward prediction of operating conditions with dual closed-loop control. Compared with existing dust removal systems, it has the following technical advantages: This system addresses the industry pain point of lagging control in existing dust removal systems. By directly acquiring cutting power and cutting action data through the roadheader's working condition sensing unit, and combining this with a pre-calibrated mapping model to predict dust generation, the system completes the matching and output of foam parameters before dust is generated during cutting operations. This achieves synchronous response between cutting dust generation and foam dust removal, suppressing dust generation at its source, significantly reducing dust diffusion, and improving the timeliness and effectiveness of dust control.

[0020] This system constructs a dual-closed-loop control architecture. The inner loop achieves closed-loop parameter control of the entire foam generation process through a multi-parameter feedback unit, which can correct parameter deviations in the execution stage in real time, ensuring the consistency between the actual foam output parameters and the control commands, and improving the system's control accuracy. The outer loop achieves closed-loop optimization of dust removal effect through a dust removal effect verification unit, which can adjust foam parameters according to the actual dust concentration at the working face, ensuring that the dust removal effect always meets safety requirements. At the same time, it can realize online iterative optimization of the control model, allowing the system's control logic to continuously adapt to changes in underground coal and rock conditions and working conditions, improving the system's scenario adaptability and long-term operational stability.

[0021] This system achieves deep linkage between the dust removal system and the working conditions of the roadheader. It can adjust the output parameters of the foam in real time according to the changes in cutting power. When the dust generation increases, the dust suppression ability of the foam is enhanced simultaneously, and when the dust generation decreases, the foam output is reduced simultaneously. While ensuring the dust removal effect on the working face, it significantly reduces the ineffective consumption of water resources and foaming agent, and lowers the operating cost of the system.

[0022] This system enables coordinated start-stop control of the dust removal system and the entire roadheader. It can be activated in advance before the cutting mechanism starts to form a pre-covered foam layer in the cutting area to prevent dust diffusion at the initial stage of cutting. It can also be delayed in shutting down after the cutting mechanism stops to allow residual suspended dust on the working face to settle. This achieves dust control throughout the entire roadheader operation process. At the same time, it eliminates the need for operators to operate the dust removal system independently, simplifying the operation process and reducing the operational burden on operators.

[0023] This system possesses comprehensive fault diagnosis and safety protection capabilities. It can monitor the operating status and data transmission status of each unit in real time, promptly detect abnormalities and faults during system operation and issue alarm reminders. At the same time, in the event of a local fault, it can automatically switch to a safe operation mode to ensure the stable operation of the basic dust removal function, avoid the loss of control over dust concentration at the working surface due to local faults, improve the system's operational reliability under harsh underground working conditions, and ensure the safety of underground operations.

[0024] The system has clearly defined modules and connections, and the installation and deployment process does not require major modifications to the main structure of the roadheader. It can be directly adapted to existing mainstream roadheader models, making it easy to promote and apply in roadheader working faces. At the same time, the system has online self-optimization capabilities, eliminating the need for operators to periodically calibrate and modify the control model, which greatly reduces the system's manual maintenance costs.

[0025] This system, through dual-point dust concentration collection, can comprehensively grasp the dust distribution status of the entire working face. It can not only effectively suppress dust generation sources, but also ensure that the dust concentration in the driver's operating area meets safety requirements. This comprehensively improves the working environment of the tunneling face, reduces the long-term harm of dust to the health of workers, and reduces the safety hazard of dust accumulation leading to explosions at the working face. Attached Figure Description

[0026] Figure 1 A schematic diagram of the composition of the adaptive foam dust removal control system based on the cutting power feedback of a roadheader provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the electrical connection relationship of the adaptive foam dust removal control system based on the cutting power feedback of a roadheader, provided in an embodiment of the present invention. Detailed Implementation

[0027] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0028] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this application. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0029] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present application. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0030] In the description of this invention, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating a connection between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0031] Example The adaptive foam dust removal control system based on the cutting power feedback of a roadheader provided in this embodiment, such as Figures 1-2 As shown, it includes a roadheader condition sensing unit, a main control unit, a foam generation execution unit, a multi-parameter feedback unit, and a dust removal effect verification unit, wherein: The signal acquisition end of the roadheader condition sensing unit is connected to the cutting drive module and cutting action execution mechanism of the roadheader, and the signal output end of the roadheader condition sensing unit is connected to the first signal input end of the main control unit. It is used to collect the operating power data and cutting action status data of the roadheader cutting mechanism in real time, and transmit the collected data to the main control unit. The second signal input terminal of the main control unit is connected to the signal output terminal of the multi-parameter feedback unit, the third signal input terminal of the main control unit is connected to the signal output terminal of the dust removal effect verification unit, and the signal output terminal of the main control unit is connected to the control terminal of the foam generation execution unit. It is used to receive data transmitted by the roadheader working condition sensing unit, the multi-parameter feedback unit and the dust removal effect verification unit, generate foam control benchmark instructions based on the pre-stored mapping model of cutting power and dust generation, and perform closed-loop correction of the foam control benchmark instructions according to the feedback data of the multi-parameter feedback unit and the dust removal effect verification unit, and output the final foam control instructions to the foam generation execution unit. The installation end of the foam generating actuator is fixed to the front end of the cutting mechanism of the roadheader. The medium input end of the foam generating actuator is connected to a water supply pipe and a foaming agent storage container. It is used to receive foam control instructions output by the main control unit, adjust its own operating parameters, and output dust removal foam with corresponding parameters to the dust-generating area of ​​the cutting mechanism of the roadheader. The signal acquisition end of the multi-parameter feedback unit is set on the medium delivery pipeline and foaming actuator of the foam generating execution unit. It is used to collect the real-time operating parameters of the foam generating execution unit and feed the collected parameters back to the main control unit. The signal acquisition terminals of the dust removal effect verification unit are respectively set on the downwind side of the driver's operating area and the cutting dust generation area of ​​the roadheader. They are used to collect the total dust concentration and respirable dust concentration data of the tunneling face in real time, and feed the collected dust concentration data back to the main control unit.

[0032] This solution constructs a complete adaptive foam dust suppression control system architecture, clarifying the connection relationships and collaborative operation logic of each unit. The roadheader's condition sensing unit directly connects to the roadheader's cutting drive module and cutting action actuator, enabling real-time acquisition of the cutting mechanism's operating power and action status data. This provides the system with front-end condition information directly related to the dust generation process, avoiding the response lag problem caused by traditional dust suppression systems relying solely on dust concentration feedback. The main control unit simultaneously receives three types of data: condition sensing, multi-parameter feedback, and dust suppression effect verification. It can first generate foam control baseline commands based on cutting power-related data, and then correct the commands by combining real-time operation feedback and on-site dust suppression effects, achieving precise matching between control commands and actual on-site needs. The foam generation actuator is fixed at the front end of the roadheader's cutting mechanism, directly delivering dust suppression foam to the cutting dust generation area, suppressing dust generation at its source and reducing dust diffusion to the work area. The multi-parameter feedback unit can collect operating parameters throughout the entire foam generation process in real time, providing real-time status feedback for the execution stage to the main control unit, ensuring consistency between foam output parameters and control commands. The dust removal effect verification unit simultaneously collects dust concentration data from the driver's operating area and the downwind side of the cutting dust generation area, which can comprehensively reflect the actual dust removal effect at the working face and provide complete on-site basis for the correction of control commands. The entire system forms a complete closed-loop operation of working condition prediction, parameter execution, status feedback, and effect verification. It can continuously adapt to changes in working conditions during roadheader operation, maintain a stable dust removal effect, and has clear signal transmission paths and well-defined operating logic between units. It can adapt to the complex underground working environment and ensure long-term stable operation of the system.

[0033] Specifically, in this embodiment, the roadheader condition sensing unit includes a cutting power acquisition module, a cutting action acquisition module, and a data preprocessing module; The signal acquisition end of the cutting power acquisition module is electrically connected to the drive motor of the cutting mechanism of the roadheader. It is used to acquire the three-phase voltage and three-phase current data of the cutting drive motor in real time and calculate the real-time cutting operation power. The signal acquisition terminal of the cutting action acquisition module is connected to the displacement sensors of the feed cylinder, slewing cylinder and lifting cylinder of the cutting mechanism of the roadheader. It is used to acquire the feed speed, slewing angle and lifting height data of the cutting mechanism to obtain the cutting action status data. The signal input terminal of the data preprocessing module is connected to the signal output terminals of the cutting power acquisition module and the cutting action acquisition module, respectively. The signal output terminal of the data preprocessing module is connected to the first signal input terminal of the main control unit. It is used to filter, reduce noise and normalize the acquired power data and action status data before transmitting them to the main control unit.

[0034] This solution further defines the internal modules and connections of the roadheader's operating condition sensing unit. The cutting power acquisition module directly connects to the drive motor of the cutting mechanism, calculating real-time cutting power by collecting three-phase voltage and current data. This accurately reflects the actual load state of the cutting mechanism during coal and rock cutting, providing accurate basic data for predicting dust generation. The cutting motion acquisition module connects to the displacement sensors of each cylinder of the cutting mechanism, collecting data on the cutting mechanism's feed speed, rotation angle, and lifting height. This comprehensively monitors the cutting mechanism's operational status. Different cutting motions correspond to different dust generation ranges and intensities; combining motion data allows for more accurate predictions of dust generation conditions. The data preprocessing module filters, reduces noise, and normalizes the collected power and motion status data, eliminating interference from the complex electromagnetic environment underground. This ensures the data transmitted to the main control unit has sufficient accuracy and stability, preventing erroneous control commands from the main control unit due to data anomalies and improving the overall control accuracy of the system.

[0035] Specifically, in this embodiment, the main control unit has a built-in model storage module, a feedforward control module, a closed-loop correction module, and an instruction output module. The model storage module is used to store the pre-calibrated mapping model between cutting power and dust generation, as well as the benchmark library of foam operating parameters that match the dust generation. The signal input end of the feedforward control module is connected to the output end of the model storage module and the working condition sensing unit of the roadheader. It is used to call the mapping model to calculate the real-time predicted dust generation based on the received real-time cutting power data and cutting action status data, match the corresponding foam operation parameter benchmark value, and generate foam control benchmark instructions. The signal input terminal of the closed-loop correction module is connected to the output terminals of the feedforward control module, the multi-parameter feedback unit, and the dust removal effect verification unit. It is used to track and correct the foam control benchmark command based on the real-time operating parameter data of the multi-parameter feedback unit, and at the same time, iteratively optimize the foam operating parameter benchmark library based on the dust concentration data of the dust removal effect verification unit to generate the final foam control command. The signal input terminal of the instruction output module is connected to the output terminal of the closed-loop correction module, and the signal output terminal of the instruction output module is connected to the control terminal of the foam generation execution unit. It is used to convert the final foam control instruction into a drive signal and output it to the foam generation execution unit.

[0036] This solution further defines the internal modules and operational logic of the main control unit. The model storage module stores a pre-calibrated mapping model between cutting power and dust generation, as well as a benchmark library of foam operating parameters matched to dust generation. This provides a unified matching basis for the system's control process, allowing the system to quickly complete parameter matching and command generation after receiving operating data. The feedforward control module, based on real-time cutting power and cutting action status data, calls the mapping model to calculate the real-time predicted dust generation, matches the corresponding benchmark values ​​of foam operating parameters, and generates benchmark commands for foam control. This allows for the preset of foam output parameters before dust is generated during the cutting operation, enabling the foam output to start synchronously with the dust generation process, suppressing dust at its source and solving the lag problem of traditional dust feedback control. The closed-loop correction module can track and correct the foam control baseline command by combining real-time operating data from the multi-parameter feedback unit. Simultaneously, it iteratively optimizes the foam operating parameter baseline library by combining dust concentration data from the dust removal effect verification unit. This ensures that the foam output parameters not only match the predicted dust generation but also adapt to parameter deviations and changes in on-site dust removal effect during actual operation, guaranteeing that the foam output parameters always align with actual dust removal needs. Furthermore, it allows the system's control logic to be continuously optimized during operation, improving the long-term control accuracy of the system. The command output module converts the final foam control command into a drive signal and outputs it to the foam generation execution unit, ensuring that the control commands of the main control unit are accurately executed, achieving precise control of the foam generation execution unit.

[0037] Specifically, in this embodiment, the foam generation execution unit includes a water supply control module, a foaming agent proportioning module, a gas-liquid mixing foaming module, and a foam spraying module; The water supply control module is connected to an external water supply pipe at its inlet end, and its control end is connected to the signal output end of the main control unit to adjust the water supply flow and pressure according to the foam control command. The inlet of the foaming agent mixing module is connected to the outlet of the water supply control module and the foaming agent storage container, respectively. The control end of the foaming agent mixing module is connected to the signal output end of the main control unit, which is used to adjust the addition ratio of the foaming agent according to the foam control command and output the foaming liquid of the set concentration. The inlet end of the gas-liquid mixing foaming module is connected to the outlet end of the foaming agent proportioning module. The air inlet end of the gas-liquid mixing foaming module is connected to a compressed air pipeline. The control end of the gas-liquid mixing foaming module is connected to the signal output end of the main control unit. It is used to adjust the air inlet pressure and air inlet flow according to the foam control command, and mix the foaming liquid with the compressed air to generate dust removal foam with the corresponding foaming ratio. The foam injection module's inlet end is connected to the outlet end of the gas-liquid mixing foaming module. The injection nozzle of the foam injection module faces the cutting head of the roadheader's cutting mechanism and the dust-generating area, and is used to uniformly spray dust removal foam to the dust-generating source.

[0038] This solution further defines the internal modules and connections of the foam generation execution unit. The water supply control module adjusts the water flow and pressure according to foam control commands, providing a stable and suitable water supply foundation for the foaming process and ensuring the supply of foaming liquid meets control requirements. The foaming agent proportioning module adjusts the addition ratio of foaming agent according to foam control commands, outputting foaming liquid of a set concentration. This allows for precise control of the foaming liquid concentration, which directly affects the foaming effect and dust removal performance. Precise proportioning ensures the generated foam has suitable dust removal capabilities while avoiding ineffective consumption of foaming agent. The gas-liquid mixing foaming module adjusts the inlet pressure and flow according to foam control commands, mixing the foaming liquid with compressed air to generate dust-removing foam with a corresponding expansion ratio. This allows for precise control of the foam expansion ratio, as different expansion ratios are suitable for different dust generation types and diffusion states. Precise control ensures the generated foam has suitable dust-collecting performance. The spray nozzle of the foam spraying module is directed towards the cutting head of the roadheader's cutting mechanism and the dust-generating area. It can evenly spray dust-suppressing foam to the dust source, quickly envelop and settle the dust generated during the cutting process, reduce the spread of dust to the working area, and improve the dust suppression effect.

[0039] Specifically, in this embodiment, the multi-parameter feedback unit includes a water supply parameter acquisition module, a foaming liquid parameter acquisition module, a compressed air parameter acquisition module, and a foam parameter acquisition module; The water supply parameter acquisition module is installed on the inlet and outlet pipelines of the water supply control module to collect real-time flow and pressure data of the water supply. The foaming liquid parameter acquisition module is set on the outlet pipeline of the foaming agent proportioning module to collect real-time concentration and flow rate data of the foaming liquid. The compressed air parameter acquisition module is installed on the air inlet pipe of the gas-liquid mixing foaming module to collect real-time flow and pressure data of compressed air. The foam parameter acquisition module is installed on the outlet pipeline of the gas-liquid mixing foaming module to collect real-time foaming ratio and real-time flow data of the generated foam. The signal output terminals of the water supply parameter acquisition module, foaming liquid parameter acquisition module, compressed air parameter acquisition module, and foam parameter acquisition module are all connected to the second signal input terminal of the main control unit.

[0040] This solution further defines the internal modules and acquisition range of the multi-parameter feedback unit. The water supply parameter acquisition module can collect real-time flow and pressure data of the water supply process, allowing the main control unit to monitor the actual operating status of the water supply process in real time. When deviations occur between the water supply parameters and the set values, the operating parameters of the water supply control module can be adjusted promptly to ensure the stability of the water supply process. The foaming liquid parameter acquisition module can collect real-time concentration and flow data of the foaming liquid, allowing the main control unit to monitor the mixing ratio and supply of the foaming liquid in real time. This allows for timely correction of the operating parameters of the foaming agent mixing module, ensuring that the concentration and flow of the foaming liquid meet the control requirements and providing a reliable foundation for stable foaming. The compressed air parameter acquisition module can collect real-time flow and pressure data of compressed air, allowing the main control unit to monitor the operating status of the air intake process in real time. This allows for timely adjustment of the air intake parameters of the gas-liquid mixing foaming module, ensuring that the gas-liquid mixing ratio meets the foaming requirements and preventing the foam expansion ratio from failing to meet the set requirements due to deviations in the air intake parameters. The foam parameter acquisition module can collect real-time foam expansion ratio and real-time flow data of the generated foam, allowing the main control unit to directly grasp the actual parameters of the final output foam, directly verify the execution effect of the entire foam generation process, form a closed-loop feedback of the entire foam generation process, ensure that the final output foam parameters are consistent with the control instructions of the main control unit, and further improve the accuracy of system control.

[0041] Specifically, in this embodiment, the dust removal effect verification unit includes a first dust collection module, a second dust collection module, and a data calibration module; The first dust collection module is fixedly installed at the operator's cab of the roadheader to collect real-time data on total dust concentration and respirable dust concentration in the operator's operating area. The second dust collection module is fixedly installed on the downwind side of the cutting mechanism of the roadheader, and the horizontal distance between it and the cutting head is kept within a preset range. It is used to collect data on the total dust concentration and respirable dust concentration after the dust is diffused in the cutting dust generation area in real time. The signal input terminal of the data calibration module is connected to the signal output terminals of the first dust collection module and the second dust collection module, respectively. The signal output terminal of the data calibration module is connected to the third signal input terminal of the main control unit. It is used to synchronously calibrate and remove outliers from the two collected dust concentration data before transmitting them to the main control unit.

[0042] This solution further defines the internal modules and installation layout of the dust removal effect verification unit. The first dust collection module is fixedly installed at the operator's cab of the roadheader, collecting real-time data on total dust concentration and respirable dust concentration in the operator's area. This directly reflects the dust control effect in the area where the workers are located, ensuring that the workers' working environment meets safety requirements. The second dust collection module is fixedly installed on the leeward side of the roadheader's cutting mechanism, collecting real-time data on total dust concentration and respirable dust concentration after the dust has diffused from the cutting dust-generating area. This directly reflects the dust suppression effect at the dust source and the dust diffusion situation, providing a comprehensive understanding of the dust distribution at the working face. The data calibration module can synchronously calibrate and remove outliers from the two collected dust concentration data, ensuring the time synchronization and accuracy of the two collected data. This avoids data anomalies caused by time deviations or underground environmental interference, providing accurate dust removal effect basis for parameter correction of the main control unit. This allows the system's control to precisely adapt to the actual dust removal effect, ensuring effective dust control throughout the entire working face.

[0043] Specifically, in this embodiment, the closed-loop correction module has a built-in parameter iteration optimization submodule. The parameter iteration optimization submodule is used to compare the real-time dust concentration data collected by the dust removal effect verification unit with the preset dust concentration threshold. When the real-time dust concentration data exceeds the preset threshold, the flow rate and foaming ratio parameters of the foam output are adjusted upward by a preset step size. At the same time, the adjusted parameters and the corresponding cutting power and dust generation data are stored in the model storage module to perform online iterative optimization on the cutting power and dust generation mapping model and the foam operation parameter benchmark library.

[0044] This solution further defines the internal sub-modules and operational logic of the closed-loop correction module. The parameter iteration optimization sub-module compares the real-time dust concentration data collected by the dust removal effect verification unit with the preset dust concentration threshold to directly determine whether the current dust removal effect meets the requirements. When the real-time dust concentration data exceeds the preset threshold, the flow rate and foaming ratio parameters of the foam output are adjusted upwards by a preset step size, which can quickly improve the dust removal capacity of the system and bring the dust concentration back to the required range, ensuring the safety of the working environment. At the same time, the parameter iteration optimization sub-module can store the adjusted parameters and the corresponding cutting power and dust generation data into the model storage module, and perform online iterative optimization of the cutting power and dust generation mapping model and the foam operation parameter benchmark library. This allows the system's control logic to continuously adapt to different coal and rock conditions and changes in the working environment underground, avoiding the decrease in control accuracy caused by the mismatch between the pre-calibrated model and the actual working conditions on site. As the system is used, the accuracy and adaptability of the control will continue to improve, eliminating the need for frequent manual calibration and modification of the model, reducing the manual maintenance cost of the system, and improving the system's adaptability to different working scenarios.

[0045] Specifically, in this embodiment, the foam spraying module includes an annular spraying frame and multiple sets of adjustable spray nozzles. The annular spraying frame is coaxially fixed to the front end of the cutting arm of the roadheader cutting mechanism and arranged around the rear end of the cutting head. The multiple sets of adjustable spray nozzles are evenly arranged around the circumference of the annular spraying frame. The spraying angle of each set of adjustable spray nozzles can be adjusted independently. The liquid inlet end of all adjustable spray nozzles is connected to the foam outlet end of the gas-liquid mixing foaming module.

[0046] This solution further defines the structure and installation layout of the foam spraying module. The annular spraying frame is coaxially fixed to the front end of the cutting arm of the roadheader's cutting mechanism, arranged around the rear end of the cutting head. This allows the spray nozzles to always move synchronously with the cutting head. Regardless of the cutting head's feeding, rotation, or lifting movements, the spray nozzles maintain their relative position to the dust source, ensuring continuous foam coverage of the cutting area and preventing incomplete foam coverage due to the cutting head's movements. Multiple sets of adjustable spray nozzles are evenly arranged circumferentially along the annular spraying frame, achieving full circumferential foam coverage of the cutting head, avoiding blind spots, and ensuring that dust generated in all directions during cutting is promptly enveloped and settled by the foam. The spray angle of each adjustable nozzle can be independently adjusted, allowing for precise foam coverage of the area with the highest dust generation according to different cutting operation scenarios, further enhancing the source suppression effect of dust and reducing dust diffusion.

[0047] Specifically, in this embodiment, the signal input terminal of the main control unit is also connected to the overall control system of the roadheader, and is used to receive the overall start-stop signal of the roadheader and the start-stop signal of the cutting mechanism. When the start signal of the cutting mechanism is received, the main control unit starts the foam generating execution unit for a preset time. When the stop signal of the cutting mechanism is received, the main control unit shuts down the foam generating execution unit after a preset time.

[0048] This solution further defines the linkage control function of the main control unit. The main control unit connects to the overall control system of the roadheader, directly receiving start / stop signals from both the roadheader and the cutting mechanism. This enables linkage control between the dust removal system and the roadheader operation, eliminating the need for manual operation of the dust removal system and simplifying the operator's workflow. It also avoids issues such as delayed start-up or premature shutdown of the dust removal system due to untimely manual operation. When the cutting mechanism start signal is received, the main control unit pre-sets the foam generation execution unit to form a foam covering layer in the cutting area before the cutting head contacts the coal and generates dust. This suppresses dust from the moment the cutting operation begins, preventing the large amount of dust generated in the initial stage from spreading to the work area. When the cutting mechanism stop signal is received, the main control unit delays the foam generation execution unit for a pre-set time, allowing for continuous settling of dust remaining suspended in the air after cutting stops. This prevents residual dust from spreading to the work area and ensures that the dust concentration in the working environment remains under control.

[0049] Specifically, in this embodiment, the main control unit also has a built-in fault diagnosis and safety protection module. The signal input terminal of the fault diagnosis and safety protection module is connected to the output terminals of the roadheader condition sensing unit, the multi-parameter feedback unit, and the dust removal effect verification unit, respectively, to monitor the operating status of each unit in real time. When any abnormal data or fault is detected in any unit, a fault alarm signal is generated, and the system switches to a preset safe operation mode to ensure the stable operation of the basic dust removal function of the dust removal system. This solution further defines the fault diagnosis and safety protection functions of the main control unit. The fault diagnosis and safety protection module connects in real-time to the roadheader's condition sensing unit, multi-parameter feedback unit, and dust removal effect verification unit. It can monitor the operating status of each unit in real time, promptly detecting data anomalies or equipment malfunctions during system operation without requiring manual inspection, thus improving the timeliness of fault detection. When any unit detects a data anomaly or malfunction, the module generates a fault alarm signal, promptly alerting underground workers and surface control personnel to the abnormal situation. This facilitates timely troubleshooting and maintenance, preventing the fault from escalating and causing complete system failure. Simultaneously, when a fault is detected, the module automatically switches to a preset safe operating mode. Even with partial system failures, the basic dust removal function of the dust removal system remains stable, preventing complete system shutdown due to localized faults, preventing uncontrolled dust concentration at the working face, ensuring the safety of underground operations, and improving the system's operational stability and reliability under harsh underground conditions.

[0050] Working principle: This system achieves adaptive foam dust removal control through logic of roadheader condition perception, feedforward parameter matching, dual closed-loop control, and full-process status monitoring. The overall operating logic is deeply linked with the cutting operation process of the roadheader.

[0051] After installation and commissioning, the system connects with the roadheader's overall control system. When the roadheader powers on and enters the work preparation state, the system simultaneously enters standby mode, completing self-checks and initialization of each unit. When the main control unit receives the start signal from the roadheader's cutting mechanism, it will activate the foam generation unit in advance according to a preset time, spraying foam into the work area where the roadheader's cutting head is located, forming a foam covering layer before the cutting operation begins, thus preventing dust diffusion during the initial cutting start-up.

[0052] After the cutting mechanism of the roadheader begins cutting coal and rock, the roadheader's condition sensing unit continues to operate. The cutting power acquisition module collects the three-phase voltage and three-phase current data of the cutting drive motor in real time, calculates the real-time operating power of the cutting mechanism, and the cutting motion acquisition module collects the feed speed, rotation angle, and lifting height data of the cutting mechanism in real time to obtain the real-time action status of the cutting mechanism. After preprocessing, the collected power data and motion status data are transmitted to the main control unit in real time.

[0053] After receiving real-time operating data, the main control unit calls the pre-calibrated cutting power and dust generation mapping model in the model storage module, and calculates the predicted dust generation under the current operating conditions by combining the cutting action status data. Then, it matches the foam operating parameters corresponding to the predicted dust generation from the foam operating parameter benchmark library, generates foam control benchmark instructions, and sends them to the foam generation execution unit.

[0054] After receiving the control command, the foam generation execution unit adjusts the water supply flow and pressure according to the command to provide a suitable water supply for the foaming process; the foaming agent ratio module adjusts the addition ratio of the foaming agent according to the command, and outputs foaming liquid of the set concentration after mixing with the water supply; the gas-liquid mixing foaming module adjusts the intake pressure and flow of compressed air according to the command to fully mix the foaming liquid and compressed air to generate dust removal foam with the corresponding foaming ratio; finally, the dust removal foam is evenly sprayed onto the cutting head and the cutting dust generation area through the foam spraying module to encapsulate and settle the dust generated during the cutting process at the source.

[0055] Throughout the entire foam generation and spraying process, the multi-parameter feedback unit operates continuously. The water supply parameter acquisition module, foaming liquid parameter acquisition module, compressed air parameter acquisition module, and foam parameter acquisition module collect real-time operating parameters for the entire process, including water supply, foaming liquid, compressed air, and the final foam output. The collected data is then fed back to the main control unit in real time. The main control unit's closed-loop correction module compares the real-time collected operating parameters with the set parameters in the control reference command. When deviations occur between the actual and set parameters, the operating parameters of each module in the foam generation execution unit are adjusted in real time to ensure that the final output foam parameters are consistent with the control command, forming an inner-loop closed-loop control for the foam execution process.

[0056] Meanwhile, the dust removal effect verification unit continues to operate. The first dust collection module collects real-time data on total dust and respirable dust concentrations in the roadheader operator's operating area, while the second dust collection module collects real-time data on total dust and respirable dust concentrations on the downwind side of the cutting dust-generating area. After synchronous calibration and outlier removal, the two data streams are transmitted to the main control unit in real time. The main control unit's closed-loop correction module compares the real-time dust concentration data with preset safety thresholds. When the dust concentration exceeds the threshold, it adjusts the relevant parameters of the foam output to improve the system's dust suppression capability and ensure that the dust concentration at the working face meets safety requirements. Simultaneously, the adjusted foam parameters, corresponding cutting power data, and dust generation data are stored in the model storage module. This allows for online iterative optimization of the cutting power-dust generation mapping model and the foam operation parameter benchmark library, enabling the system's control logic to continuously adapt to changes in on-site operating conditions, forming an outer-loop closed-loop optimization of the dust removal effect.

[0057] When the cutting mechanism of the roadheader stops operating, the main control unit receives the stop signal of the cutting mechanism, and shuts down the foam generating execution unit after a preset delay. It continues to spray foam onto the working face to settle the residual dust that is still suspended in the air after the cutting operation stops. After the preset delay time is reached, the foam generating execution unit is shut down.

[0058] Throughout the system's operation, the fault diagnosis and safety protection module monitors the operating status and data transmission status of each unit in real time. When any unit detects data abnormalities or component failures, it immediately generates a fault alarm signal to remind operators to investigate and handle the issue. At the same time, it automatically switches to the preset safe operation mode to ensure the stable operation of the system's basic dust removal function and prevent dust concentration from getting out of control due to local faults.

[0059] How to use: The usage of this system is divided into four stages: installation and deployment, debugging and calibration, daily operation and troubleshooting. The specific operation procedures for each stage are as follows: During the installation and deployment phase, the installation of the roadheader's working condition sensing unit is completed first. The cutting power acquisition module is electrically connected to the drive motor of the roadheader's cutting mechanism. The cutting motion acquisition module is signal-interconnected with the displacement sensors of the cutting mechanism's feed cylinder, slewing cylinder, and lifting cylinder. The data preprocessing module is fixedly installed in the roadheader's electrical control box, and the signal wiring between each module and the main control unit is completed. Next, the foam generation execution unit is installed. The water inlet of the water supply control module is sealed to the underground water supply pipeline. The liquid inlet of the foaming agent proportioning module is connected to the water outlet of the water supply control module and the foaming agent storage container, respectively. The air inlet of the gas-liquid mixing foaming module is sealed to the underground compressed air pipeline. The annular spray frame is coaxially fixed to the front end of the roadheader's cutting arm, arranged around the rear end of the cutting head, and the spray angle of each nozzle is adjusted. The control circuit connection between each module and the main control unit is completed. Next, the multi-parameter feedback unit was installed, with each parameter acquisition module installed on its corresponding pipeline. The water supply parameter acquisition module was installed on the inlet and outlet pipelines of the water supply control module, the foaming liquid parameter acquisition module on the outlet pipeline of the foaming agent proportioning module, the compressed air parameter acquisition module on the inlet pipeline of the gas-liquid mixing foaming module, and the foam parameter acquisition module on the outlet pipeline of the gas-liquid mixing foaming module. Signal wiring between each acquisition module and the main control unit was then completed. Next, the dust removal effect verification unit was installed. The first dust acquisition module was fixedly installed at the operating position in the roadheader's cab, and the second dust acquisition module was fixedly installed on the leeward side of the roadheader's cutting mechanism, ensuring the acquisition end was directly facing the dust-generating area. Signal wiring between the two acquisition modules and the main control unit was completed. Finally, the main control unit was integrated and installed inside the roadheader's electrical control box. Signal connection between the main control unit and the roadheader's overall control system was completed, and the system's power supply was connected, completing the hardware installation and deployment of the entire system.

[0060] During the commissioning and calibration phase, the system was first commissioned under no-load conditions. After powering on, the system initiated a self-test program to confirm normal signal transmission in each unit. Then, the foam generation execution unit was started under no-load conditions to test the ability of the main control unit to issue and execute control commands correctly, the accuracy of parameter acquisition by the multi-parameter feedback unit, and the compliance of the foam spraying module's spray coverage with requirements. The basic operating parameters of each module were adjusted to ensure stable system operation under no-load conditions. Next, on-site working condition calibration was completed. During normal cutting operations of the roadheader, dust generation data was collected under different cutting power and cutting action conditions to establish a mapping model between cutting power and dust generation. Simultaneously, corresponding foam operating parameters were calibrated for different dust generation levels, and a foam operating parameter benchmark library was established. The mapping model and parameter benchmark library were then stored in the main control unit's model storage module. Finally, system operating parameter settings were completed. Based on the safety requirements of underground operations, a safe threshold for dust concentration at the working face was set. Based on the roadheader's operating procedures, the duration of early system start-up and delayed shutdown was set. Based on the variation in on-site working conditions, the step size for foam parameter adjustment was set, completing the system commissioning and calibration.

[0061] During daily operation, before starting the roadheader, firstly, check the connection status of all hardware components, the stability of water and compressed air supply, and the sufficiency of foaming agent in the foaming agent storage container. After confirming everything is correct, power on the system. After completing self-test, the system enters standby mode. Secondly, when the roadheader starts cutting operations, the main control unit receives the start signal from the cutting mechanism and activates the foam generation execution unit according to the preset advance time, spraying foam into the cutting area in advance to form a pre-covering layer. Throughout the cutting operation, the roadheader's operating condition sensing unit collects cutting power and cutting action data in real time and transmits it to the main control unit. The main control unit generates foam control baseline commands based on the real-time operating condition data and sends them to the foam generation execution unit to adjust the foam output parameters in real time to adapt to the current dust-generating conditions. Simultaneously, the multi-parameter feedback unit collects the operating parameters of the entire foam generation process in real time and feeds them back to the main control unit to complete the inner loop closed-loop correction. The dust removal effect verification unit collects the dust concentration data of the working face in real time and feeds it back to the main control unit to complete the outer loop closed-loop optimization and model iteration. Subsequently, when the cutting mechanism of the roadheader stops operating, the main control unit receives the stop signal from the cutting mechanism and continues to run the foam generating unit according to the preset delay time to settle the residual dust on the working face. After the delay time is reached, the foam generating unit is shut down. Finally, after the roadheader stops operating, the operating status of each component of the system is checked, foaming agent is replenished to the foaming agent storage container, residual impurities in the pipelines and nozzles are cleaned, and routine post-operation maintenance is completed. Afterward, the power supply to the system is disconnected.

[0062] During the fault handling phase, when the fault diagnosis and safety protection module detects abnormal data or component failures during system operation, it will automatically generate a fault alarm signal and switch to a safe operation mode to ensure the stable operation of basic dust removal functions. After receiving the alarm signal, operators will investigate the location and cause of the fault while ensuring operational safety. After the fault is repaired, the system will automatically exit the safe operation mode and restore normal adaptive control operation.

[0063] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. An adaptive foam dust control system based on cutting power feedback from a roadheader, characterized in that, It includes a roadheader condition sensing unit, a main control unit, a foam generation execution unit, a multi-parameter feedback unit, and a dust removal effect verification unit, among which: The signal acquisition end of the roadheader condition sensing unit is connected to the cutting drive module and the cutting action execution mechanism of the roadheader. The signal output end of the roadheader condition sensing unit is connected to the first signal input end of the main control unit. It is used to collect the operating power data and cutting action status data of the roadheader cutting mechanism in real time and transmit the collected data to the main control unit. The second signal input terminal of the main control unit is connected to the signal output terminal of the multi-parameter feedback unit, the third signal input terminal of the main control unit is connected to the signal output terminal of the dust removal effect verification unit, and the signal output terminal of the main control unit is connected to the control terminal of the foam generation execution unit. It is used to receive data transmitted by the roadheader working condition sensing unit, the multi-parameter feedback unit and the dust removal effect verification unit, generate foam control benchmark instructions based on the pre-stored mapping model of cutting power and dust generation, and perform closed-loop correction of the foam control benchmark instructions according to the feedback data of the multi-parameter feedback unit and the dust removal effect verification unit, and output the final foam control instructions to the foam generation execution unit. The installation end of the foam generating execution unit is fixed to the front end of the cutting mechanism of the roadheader. The medium input end of the foam generating execution unit is connected to a water supply pipe and a foaming agent storage container. It is used to receive foam control instructions output by the main control unit, adjust its own operating parameters, and output dust removal foam with corresponding parameters to the dust-generating area of ​​the cutting mechanism of the roadheader. The signal acquisition terminal of the multi-parameter feedback unit is set on the medium delivery pipeline and foaming actuator of the foam generating execution unit, and is used to collect the real-time operating parameters of the foam generating execution unit and feed the collected parameters back to the main control unit. The signal acquisition terminals of the dust removal effect verification unit are respectively set on the downwind side of the driver's operating area and the cutting dust generation area of ​​the roadheader, and are used to collect the total dust concentration and respirable dust concentration data of the tunneling face in real time, and feed back the collected dust concentration data to the main control unit.

2. The adaptive foam dust control system based on cutting power feedback of a roadheader according to claim 1, characterized in that, The roadheader condition sensing unit includes a cutting power acquisition module, a cutting action acquisition module, and a data preprocessing module. The signal acquisition terminal of the cutting power acquisition module is electrically connected to the drive motor of the cutting mechanism of the roadheader, and is used to acquire the three-phase voltage and three-phase current data of the cutting drive motor in real time, and calculate the real-time cutting operation power. The signal acquisition terminal of the cutting action acquisition module is connected to the displacement sensors of the feed cylinder, slewing cylinder and lifting cylinder of the cutting mechanism of the roadheader, and is used to acquire the feed speed, slewing angle and lifting height data of the cutting mechanism to obtain the cutting action status data. The signal input terminal of the data preprocessing module is connected to the signal output terminals of the cutting power acquisition module and the cutting action acquisition module, respectively. The signal output terminal of the data preprocessing module is connected to the first signal input terminal of the main control unit. It is used to filter, reduce noise and normalize the acquired power data and action status data before transmitting them to the main control unit.

3. The adaptive foam dust control system based on cutting power feedback of a roadheader according to claim 1, characterized in that, The main control unit has a built-in model storage module, feedforward control module, closed-loop correction module and instruction output module. The model storage module is used to store the pre-calibrated mapping model between cutting power and dust generation, as well as a benchmark library of foam operating parameters that match the dust generation. The signal input terminal of the feedforward control module is connected to the output terminal of the model storage module and the working condition sensing unit of the roadheader. It is used to call the mapping model to calculate the real-time predicted dust generation based on the received real-time cutting power data and cutting action status data, match the corresponding foam operation parameter benchmark value, and generate foam control benchmark instructions. The signal input terminal of the closed-loop correction module is connected to the output terminals of the feedforward control module, the multi-parameter feedback unit, and the dust removal effect verification unit. It is used to track and correct the foam control benchmark command based on the real-time operating parameter data of the multi-parameter feedback unit, and at the same time to iteratively optimize the foam operating parameter benchmark library based on the dust concentration data of the dust removal effect verification unit to generate the final foam control command. The signal input terminal of the instruction output module is connected to the output terminal of the closed-loop correction module, and the signal output terminal of the instruction output module is connected to the control terminal of the foam generation execution unit, which is used to convert the final foam control instruction into a drive signal and output it to the foam generation execution unit.

4. The adaptive foam dust control system based on cutting power feedback of a roadheader according to claim 1, characterized in that, The foam generation execution unit includes a water supply control module, a foaming agent proportioning module, a gas-liquid mixing foaming module, and a foam spraying module. The water supply control module is connected to an external water supply pipe at its inlet end, and the control end of the water supply control module is connected to the signal output end of the main control unit for adjusting the water supply flow and water supply pressure according to the foam control command. The inlet of the foaming agent proportioning module is connected to the outlet of the water supply control module and the foaming agent storage container, respectively. The control terminal of the foaming agent proportioning module is connected to the signal output terminal of the main control unit, which is used to adjust the addition ratio of the foaming agent according to the foam control command and output foaming liquid of the set concentration. The inlet end of the gas-liquid mixing foaming module is connected to the outlet end of the foaming agent proportioning module. The air inlet end of the gas-liquid mixing foaming module is connected to a compressed air pipeline. The control end of the gas-liquid mixing foaming module is connected to the signal output end of the main control unit. It is used to adjust the air inlet pressure and air inlet flow according to the foam control command, and mix the foaming liquid with the compressed air to generate dust removal foam with the corresponding foaming ratio. The foam injection module has its inlet end connected to the outlet end of the gas-liquid mixing foaming module. The injection nozzle of the foam injection module faces the cutting head of the roadheader's cutting mechanism and the dust-generating area, and is used to uniformly spray the dust removal foam to the dust source.

5. The adaptive foam dust control system based on cutting power feedback of a roadheader according to claim 1, characterized in that, The multi-parameter feedback unit includes a water supply parameter acquisition module, a foaming liquid parameter acquisition module, a compressed air parameter acquisition module, and a foam parameter acquisition module; The water supply parameter acquisition module is installed on the inlet and outlet pipelines of the water supply control module to collect real-time flow and pressure data of the water supply. The foaming liquid parameter acquisition module is installed on the outlet pipeline of the foaming agent proportioning module and is used to collect real-time concentration and flow rate data of the foaming liquid. The compressed air parameter acquisition module is installed on the air inlet pipe of the gas-liquid mixing foaming module and is used to collect real-time flow and pressure data of compressed air. The foam parameter acquisition module is installed on the outlet pipe of the gas-liquid mixing foaming module and is used to collect the real-time foaming ratio and real-time flow data of the generated foam. The signal output terminals of the water supply parameter acquisition module, foaming liquid parameter acquisition module, compressed air parameter acquisition module, and foam parameter acquisition module are all connected to the second signal input terminal of the main control unit.

6. The adaptive foam dust control system based on cutting power feedback of a roadheader according to claim 1, characterized in that, The dust removal effect verification unit includes a first dust collection module, a second dust collection module, and a data calibration module; The first dust collection module is fixedly installed at the operator's cab of the roadheader to collect real-time data on total dust concentration and respirable dust concentration in the operator's operating area. The second dust collection module is fixedly installed on the downwind side of the cutting mechanism of the roadheader, and the horizontal distance between it and the cutting head is kept within a preset range. It is used to collect data on the total dust concentration and respirable dust concentration after the dust is diffused in the cutting dust generation area in real time. The signal input terminal of the data calibration module is connected to the signal output terminals of the first dust collection module and the second dust collection module, respectively. The signal output terminal of the data calibration module is connected to the third signal input terminal of the main control unit. It is used to synchronously calibrate and remove outliers from the two collected dust concentration data before transmitting them to the main control unit.

7. The adaptive foam dust control system based on cutting power feedback of a roadheader according to claim 3, characterized in that, The closed-loop correction module has a built-in parameter iteration optimization submodule. The parameter iteration optimization submodule is used to compare the real-time dust concentration data collected by the dust removal effect verification unit with the preset dust concentration threshold. When the real-time dust concentration data exceeds the preset threshold, the flow rate and foaming ratio parameters of the foam output are adjusted upward by a preset step size. At the same time, the adjusted parameters and the corresponding cutting power and dust generation data are stored in the model storage module to perform online iterative optimization on the cutting power and dust generation mapping model and the foam operation parameter benchmark library.

8. The adaptive foam dust control system based on cutting power feedback of a roadheader according to claim 4, characterized in that, The foam spraying module includes an annular spraying frame and multiple sets of adjustable spray nozzles. The annular spraying frame is coaxially fixed to the front end of the cutting arm of the roadheader cutting mechanism and arranged around the rear end of the cutting head. The multiple sets of adjustable spray nozzles are evenly arranged around the circumference of the annular spraying frame. The spraying angle of each set of adjustable spray nozzles can be adjusted independently. The liquid inlet end of all adjustable spray nozzles is connected to the foam outlet end of the gas-liquid mixing foaming module.

9. The adaptive foam dust control system based on cutting power feedback of a roadheader according to claim 1, characterized in that, The signal input terminal of the main control unit is also connected to the overall control system of the roadheader, and is used to receive the start / stop signal of the roadheader and the start / stop signal of the cutting mechanism. When the start signal of the cutting mechanism is received, the main control unit starts the foam generating execution unit after a preset time. When the stop signal of the cutting mechanism is received, the main control unit shuts down the foam generating execution unit after a preset time.

10. The adaptive foam dust control system based on cutting power feedback of a roadheader according to any one of claims 1-9, characterized in that, The main control unit also has a built-in fault diagnosis and safety protection module. The signal input terminal of the fault diagnosis and safety protection module is connected to the output terminals of the tunnel boring machine working condition sensing unit, multi-parameter feedback unit, and dust removal effect verification unit, respectively. It is used to monitor the operating status of each unit in real time. When any unit is detected to have abnormal data or fault, a fault alarm signal is generated, and the system switches to the preset safe operation mode to ensure the stable operation of the basic dust removal function of the dust removal system.

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