Fully-mechanized excavation face submerged foam adjusting system based on real-time dust concentration monitoring

Abstract

The invention provides a fully-mechanized excavation face submerged foam adjusting system based on real-time dust concentration monitoring, belongs to the technical field of dust treatment of an underground coal mine fully-mechanized excavation face, and aims at solving the problems that an existing fully-mechanized excavation face foam dust falling system is one-sided in monitoring, lagged in adjustment, poor in parameter adaptability and unstable in dust falling effect. The system comprises a global dust concentration monitoring module, a submerged foam generating and spraying module, a multi-parameter coordinated regulation module and a main control module, dust distribution data are obtained through full-section monitoring, the main control module generates an adjusting instruction in combination with working conditions, the multi-parameter cooperative adjusting module synchronously adjusts foam related parameters, the spraying module forms a full-section submerged foam barrier, and precise dust treatment is achieved in cooperation with closed-loop feedback and fault redundancy protection. The device adapts to all working conditions of the roadheader, improves the stability of the dust falling effect, reduces resource consumption, enhances the reliability of the system, and improves the underground working environment.

Description

Technical Field

[0001] This invention relates to the field of dust control technology at fully mechanized tunneling faces in coal mines, specifically to a submerged foam regulation system for fully mechanized tunneling faces based on real-time dust concentration monitoring. Background Technology

[0002] During underground longwall tunneling operations in coal mines, the cutting of coal and rock generates a large amount of dust, which not only endangers the health of underground workers but also poses a safety hazard of dust explosions. Therefore, it is a key area for safety management and occupational health protection in coal mines. Currently, the most commonly used dust suppression methods at longwall tunneling faces are spray dust suppression and conventional foam dust suppression, but these methods have many limitations in practical application and cannot meet the specific needs of on-site operations.

[0003] Most existing foam dust suppression systems use fixed-parameter foaming and spraying modes, which cannot adjust operating parameters according to dynamic changes in on-site dust concentration. This results in either wasted foaming agent, water, and electricity resources under low-concentration dust-generating conditions, or insufficient dust suppression capacity under high-concentration dust-generating conditions, failing to adapt to real-time fluctuations in dust generation during tunneling. Existing dust monitoring methods are mostly single-point fixed monitoring, which can only obtain concentration data at a single point. This cannot fully reflect the dust distribution across the entire cross-section of the tunnel face, nor can it accurately capture the entire process of dust generation and diffusion. Consequently, adjustments lack comprehensive data support, resulting in delayed and insufficiently targeted adjustments.

[0004] Meanwhile, existing foam adjustment methods mostly involve independent adjustment of a single parameter, allowing only individual adjustment of the liquid supply flow rate or foaming air pressure. However, the dust suppression effect, stability, and coverage of foam are determined by multiple parameters, including air pressure, liquid supply flow rate, foaming agent ratio, and spraying posture. Adjusting a single parameter cannot adapt the foam performance to the actual needs of the site, easily leading to problems such as poor foaming effect, incomplete coverage, and short stabilization time. Existing foam spraying structures are mostly deployed at fixed points and in fixed directions, unable to dynamically adjust the spraying range according to the working conditions of the roadheader. When the roadheader's cutting head moves, it is easy to encounter problems with inadequate coverage of dust sources, and it is also difficult to form a continuous barrier across the entire cross-section. Dust can easily spread outward from the blind spots, resulting in insufficient stability of the dust suppression effect.

[0005] In addition, most existing dust suppression systems operate in an open-loop control mode, lacking a complete closed-loop feedback adjustment link. This prevents them from dynamically adjusting parameters based on actual changes in dust concentration after suppression. Consequently, the systems exhibit poor adaptability when on-site operating conditions and roadway environmental conditions change, failing to maintain stable dust suppression effects over long periods. Furthermore, existing systems lack robust fault self-diagnosis and redundancy protection mechanisms. A failure in a single component can easily lead to a significant reduction in the entire system's dust suppression capacity, making it difficult to adapt to the complex and harsh underground working environment.

[0006] To address this, a submerged foam control system for tunnel faces based on real-time dust concentration monitoring is proposed. Summary of the Invention

[0007] The present invention aims to solve the problems mentioned in the background art by providing a submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring.

[0008] The specific technical solution is as follows: A submerged foam control system for tunneling faces based on real-time dust concentration monitoring includes a global dust concentration monitoring module, a submerged foam generation and injection module, a multi-parameter coordinated control module, and a main control module, wherein: The full-area dust concentration monitoring module is deployed at full-section measuring points on the tunnel face to collect real-time data on total dust concentration and respirable dust concentration in different areas of the tunnel face, and transmits the collected concentration data to the main control module in real time. The main control module is electrically connected to the global dust concentration monitoring module and the multi-parameter collaborative adjustment module, respectively. It is used to receive concentration data, combine the preset dust concentration threshold with the tunneling face working condition data, generate multi-parameter adjustment instructions, and send the adjustment instructions to the multi-parameter collaborative adjustment module. The multi-parameter coordinated adjustment module is connected to the pipeline and control of the submerged foam generating and spraying module, and is used to receive adjustment commands from the main control module and synchronously adjust the foaming air pressure, liquid supply flow rate, foaming agent concentration and spray coverage parameters of the submerged foam generating and spraying module. The submerged foam generating and spraying module is deployed at the tunneling end of the roadheader and around the entire cross-section of the roadheader face. It is used to receive the adjustment output of the multi-parameter coordinated adjustment module, generate submerged foam with corresponding parameters, and spray it onto the dust-generating area of ​​the roadheader face to form a full-section submerged dust barrier.

[0009] As a preferred embodiment of the present invention, the global dust concentration monitoring module includes multiple sets of laser dust detection substations, a data acquisition and transmission unit, and a working condition linkage calibration unit. The multiple sets of laser dust detection substations are respectively deployed at preset measuring points at the end of the cutting section of the roadheader, the operator's operating position of the roadheader, the upper air inlet and lower air inlet of the return air side of the roadway, and both sides of the roadway of the roadway, collecting total dust and respirable dust concentration data from dust sources, personnel operating areas, and roadway diffusion areas, respectively. The data acquisition and transmission unit transmits the concentration data from each substation to the main control module after time synchronization processing. The working condition linkage calibration unit collects the operating current and travel speed data of the cutting motor of the roadheader, dynamically calibrates the concentration data, and eliminates the interference of tunneling operation vibration on the detection accuracy.

[0010] As a preferred embodiment of the present invention, the main control module has a built-in dust concentration grading control unit and a working condition matching unit. The dust concentration grading control unit has multiple preset dust concentration threshold ranges that increase progressively, and matches corresponding foam control parameter sets for different concentration threshold ranges. The working condition matching unit is connected to the control system of the roadheader, and obtains the working condition data of the roadheader's cutting, traveling, stopping, and spraying operations in real time. It dynamically corrects the adjustment commands based on the concentration data, increases the foam coverage intensity when the roadheader is cutting, and lowers the foam output parameters to the standby threshold when the roadheader is stopped.

[0011] In a preferred embodiment of the present invention, the multi-parameter coordinated adjustment module includes an air pressure adjustment unit, a liquid supply adjustment unit, a foaming agent ratio adjustment unit, and a spray attitude adjustment unit. The air pressure adjustment unit is connected to the air source pipeline of the submerged foam generating spray module and is used to adjust the output pressure and flow rate of the foaming air source. The liquid supply adjustment unit is connected to the liquid supply pipeline of the submerged foam generating spray module and is used to adjust the output flow rate of the foaming base liquid. The foaming agent ratio adjustment unit is connected in series at the front end of the liquid supply pipeline and is used to adjust the mixing ratio of the foaming agent and water. The spray attitude adjustment unit is connected to the spray assembly of the submerged foam generating spray module and is used to adjust the spray angle, swing amplitude, and spray range of the spray assembly.

[0012] As a preferred embodiment of the present invention, the submerged foam generating and spraying module includes a multi-channel foam generating unit, an annular spraying frame, and multiple sets of directional spraying components. The annular spraying frame is fixed to the rear end of the cutting section of the roadheader and is arranged around the cutting arm. The input ends of the multi-channel foam generating units are respectively connected to the air source and liquid supply pipeline of the multi-parameter coordinated adjustment module, and the output ends are respectively connected to the annular spraying frame and each directional spraying component. The multiple sets of directional spraying components are respectively arranged at the two sides, roof, and floor of the roadway of the roadway, and cooperate with the annular spraying frame to form a foam spraying network covering the entire cross-section of the roadway. The generated submerged foam fills the entire cross-sectional space of the roadway end, forming a sealed barrier to prevent dust diffusion.

[0013] As a preferred embodiment of the present invention, the main control module also has a built-in closed-loop feedback adjustment unit. The closed-loop feedback adjustment unit receives the concentration data from the global dust concentration monitoring module in real time, compares the measured concentration value after foam adjustment with the preset target concentration value, and when the measured value is higher than the target concentration value, the foam output parameters are gradually increased. When the measured value is lower than the lower limit threshold of the target concentration value, the foam output parameters are gradually decreased, forming a fully closed-loop real-time adjustment link.

[0014] As a preferred embodiment of the present invention, the foaming agent ratio adjustment unit has a built-in concentration closed-loop control subunit. The concentration closed-loop control subunit detects the actual mixing concentration of the foaming agent in the liquid supply pipeline in real time, compares it with the target ratio concentration issued by the main control module, and automatically adjusts the output frequency of the foaming agent metering pump to achieve precise closed-loop adjustment of the foaming agent concentration. At the same time, the metering pump output is adjusted synchronously when the liquid supply flow changes to ensure the stability of the ratio concentration.

[0015] As a preferred embodiment of the present invention, the system further includes a fault self-diagnosis redundancy protection module. The fault self-diagnosis redundancy protection module is electrically connected to the main control module, the multi-parameter collaborative adjustment module, and the submerged foam generating and spraying module, respectively. It monitors the gas source pressure, liquid supply pressure, pipeline flow rate, foaming agent level, and operating status of the spraying components in real time. When a blockage of a single spraying component or an abnormal liquid supply is detected, it automatically switches to the backup pipeline, and at the same time lowers the output parameters of the faulty loop and raises the foam output parameters of the adjacent loop to ensure the continuity of the full-section submerged dust suppression barrier.

[0016] As a preferred embodiment of the present invention, each laser dust detection substation of the global dust concentration monitoring module has an intrinsically safe explosion-proof structure and a sampling frequency of not less than 10Hz. The data collected by each substation is synchronized at the millisecond level through a time synchronization protocol. Based on the synchronized multi-point concentration data, the main control module constructs a real-time distribution model of the dust concentration field of the tunnel boring machine, locates high-concentration dust-generating areas based on the distribution model, and adjusts the foam output parameters of the corresponding area spray components in a directional manner.

[0017] As a preferred embodiment of the present invention, the spray attitude adjustment unit has a built-in swing control subunit. The swing control subunit controls the swing frequency and swing angle of the annular spray frame and the directional spray assembly according to the adjustment command issued by the main control module. When the cutting part of the roadheader moves laterally, the spray direction is adjusted in sync with the movement trajectory of the cutting part to ensure that the foam always covers the dust source of the cutting. At the same time, the swing amplitude is adjusted in the dust diffusion area to expand the foam coverage area and enhance the flooding dust suppression effect.

[0018] The present invention has the following beneficial effects: By deploying dust monitoring at multiple points across the entire cross-section and combining it with data calibration based on operating conditions, the distribution of dust throughout the entire process from generation to diffusion within the tunnel face can be fully obtained. This eliminates the data bias caused by single-point monitoring and avoids interference from tunneling machine vibration on monitoring accuracy. It provides comprehensive, accurate, and real-time data support for system adjustments, allowing adjustments to adapt to changes in dust-generating conditions in advance, thus solving the problems of delayed and insufficient targeting in conventional systems.

[0019] By using a multi-parameter coordinated adjustment method, synchronous and precise control of all parameters in the foam generation and spraying process is achieved. It can simultaneously adjust various properties such as foam expansion ratio, total generation, stability, and coverage according to the actual needs on site, avoiding the problem of insufficient adaptability caused by single parameter adjustment. This ensures that the various properties of the foam can always match the dust conditions and working conditions on site, guaranteeing the stability and effectiveness of the foam dust suppression capability.

[0020] By deploying a full-section spraying network and dynamically adjusting the spraying posture, a continuous and complete full-section foam barrier can be formed at the tunneling end of the roadheader face, eliminating blind spots in the spraying coverage. At the same time, the spraying direction can be adjusted synchronously with the movement of the roadheader's cutting section, always covering the source of dust generated during cutting. The dust is adsorbed and settled the moment it is generated, while preventing the dust from spreading outward, thus avoiding the problem of dust spreading from blind spots and ensuring the stability of dust suppression effect throughout the entire operation.

[0021] The closed-loop feedback regulation mechanism can dynamically adjust the system's parameters based on the actual dust concentration changes after dust suppression. This allows the system to automatically adapt to real-time changes in the tunnel environment and operating conditions, maintaining a stable dust suppression effect without the need for frequent manual adjustments. This reduces the operational burden on on-site personnel and avoids resource waste caused by fixed parameter operation, while also reducing the consumption of foaming agents, water, electricity, and other resources.

[0022] Through a robust fault self-diagnosis and redundancy protection mechanism, the system can monitor the operating status of each pipeline and component in real time, promptly detect abnormalities during operation, and automatically switch redundant pipelines and compensate parameters of adjacent circuits. This avoids the problem of a significant decrease in the system's dust suppression capacity caused by a single component failure, ensuring the system can operate continuously and stably in the complex and harsh underground working environment, and improving the system's operational reliability and field adaptability.

[0023] The entire system can be linked and adapted to the working conditions of the roadheader. Under different working conditions of the roadheader, it automatically adjusts the corresponding operating parameters. It can ensure sufficient dust reduction capacity under high dust production conditions and reduce unnecessary resource consumption under low dust production conditions. At the same time, it can adapt to roadheader faces with different cross-sectional sizes and different models of roadheaders. It has strong versatility and field adaptability, and can effectively improve the working environment of the roadheader face and reduce occupational health hazards and safety risks caused by dust. Attached Figure Description

[0024] Figure 1 A schematic diagram of the composition of a submerged foam conditioning system for a fully mechanized tunnel face based on real-time dust concentration monitoring, provided in an embodiment of the present invention. Figure 2This is a schematic diagram of the connection relationship of a submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring, provided in an embodiment of the present invention. Detailed Implementation

[0025] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] Example The fully mechanized tunneling face submerged foam control system provided in this embodiment, based on real-time dust concentration monitoring, is as follows: Figures 1-2 As shown, it includes a global dust concentration monitoring module, a submerged foam generation and spraying module, a multi-parameter coordinated adjustment module, and a main control module, among which: The full-area dust concentration monitoring module is deployed at full-section measuring points on the tunnel face to collect real-time data on total dust concentration and respirable dust concentration in different areas of the tunnel face, and transmits the collected concentration data to the main control module in real time. The main control module is electrically connected to the global dust concentration monitoring module and the multi-parameter collaborative adjustment module, respectively. It is used to receive concentration data, combine the preset dust concentration threshold with the tunneling face working condition data, generate multi-parameter adjustment instructions, and send the adjustment instructions to the multi-parameter collaborative adjustment module. The multi-parameter coordinated adjustment module is connected to the submerged foam generating and spraying module pipeline and control system. It is used to receive adjustment commands from the main control module and synchronously adjust the foaming air pressure, liquid supply flow rate, foaming agent concentration and spray coverage parameters of the submerged foam generating and spraying module. The submerged foam generating and spraying module is deployed at the tunneling end of the roadheader and around the entire cross-section of the roadheader face. It is used to receive the adjustment output of the multi-parameter coordinated adjustment module, generate submerged foam with corresponding parameters, and spray it onto the dust-generating area of ​​the roadheader face to form a full-section submerged dust barrier.

[0030] This solution utilizes a full-section data acquisition structure to comprehensively acquire dust-related data from different locations on the workface, avoiding the data bias caused by single-point acquisition and ensuring that the acquired information fully reflects the overall dust distribution within the workface. The main control module processes the acquired data in conjunction with operational conditions, ensuring that the generated adjustment commands align with the actual on-site working conditions and avoiding ineffective adjustments divorced from reality. Through multi-parameter synchronous adjustment, the entire process parameters for foam generation and spraying can be uniformly adjusted, ensuring that the foam generation state and spraying range adapt to actual on-site needs and avoiding the inadequacy of single-parameter adjustments. The deployment method at the workface end and along the entire perimeter ensures that the generated foam completely covers the dust-generating area of ​​the workface, forming a continuous barrier structure within the workface to prevent dust from spreading to the personnel activity area and behind the tunnel, while simultaneously achieving comprehensive dust treatment within the workface.

[0031] Specifically, in this embodiment, the overall dust concentration monitoring module includes multiple sets of laser dust detection substations, a data acquisition and transmission unit, and a working condition linkage calibration unit. The multiple sets of laser dust detection substations are respectively deployed at preset measuring points at the end of the cutting section of the roadheader, the roadheader operator's operating position, the upper and lower air inlets of the return air side of the roadway, and both sides of the roadway, collecting total dust and respirable dust concentration data from dust sources, personnel operating areas, and roadway diffusion areas. The data acquisition and transmission unit performs time synchronization processing on the concentration data from each substation and transmits it to the main control module. The working condition linkage calibration unit collects the operating current and travel speed data of the roadheader's cutting motor and dynamically calibrates the concentration data to eliminate the interference of tunneling operation vibration on the detection accuracy.

[0032] This solution deploys data collection substations at dust sources, personnel activity areas, and airflow circulation areas in the tunnels. This allows for the acquisition of data on the initial dust generation location, the core personnel work area, and the dust diffusion path, comprehensively covering the entire dust generation and diffusion process. This provides comprehensive and targeted data support for subsequent adjustments. By synchronizing data from multiple substations, consistency in time between data collected from different locations is ensured, avoiding judgment biases caused by asynchronous data and guaranteeing accurate assessment of dust distribution. Furthermore, calibrating the collected data with operational equipment data eliminates the impact of vibrations and other factors during equipment operation on data acquisition accuracy. This ensures that the collected data remains stable and accurate during normal equipment operation, preventing data distortion caused by equipment operation.

[0033] Specifically, in this embodiment, the main control module has a built-in dust concentration grading control unit and a working condition matching unit. The dust concentration grading control unit has multiple preset dust concentration threshold ranges that increase progressively, and matches the corresponding foam control parameter set for different concentration threshold ranges. The working condition matching unit is connected to the control system of the roadheader, and obtains the working condition data of the roadheader's cutting, traveling, stopping, and spraying operations in real time. It dynamically corrects the adjustment commands based on the concentration data, increases the foam coverage intensity when the roadheader is cutting, and lowers the foam output parameters to the standby threshold when the roadheader is stopped.

[0034] This solution, by pre-setting multiple progressively varying concentration ranges and corresponding control parameters, can match appropriate treatment methods to different dust concentrations. This avoids resource waste caused by using excessively high output parameters at low concentrations, while ensuring sufficient processing capacity at higher concentrations, thus adapting the treatment intensity to the site conditions. By connecting to the control system of the operating equipment, the solution can acquire the equipment's operating status in real time and adjust the control commands based on different operating states. This ensures that the adjustment actions are synchronized with the equipment's operational behavior. When the equipment is performing operations with high dust generation, the corresponding processing capacity is increased in advance, avoiding the lag problem of adjusting after dust has spread. When the equipment stops operating, the output parameters are lowered to a reasonable standby state, reducing unnecessary resource consumption.

[0035] Specifically, in this embodiment, the multi-parameter coordinated adjustment module includes an air pressure adjustment unit, a liquid supply adjustment unit, a foaming agent ratio adjustment unit, and a spray attitude adjustment unit. The air pressure adjustment unit is connected to the air source pipeline of the submerged foam generating spray module and is used to adjust the output pressure and flow rate of the foaming air source. The liquid supply adjustment unit is connected to the liquid supply pipeline of the submerged foam generating spray module and is used to adjust the output flow rate of the foaming base liquid. The foaming agent ratio adjustment unit is connected in series at the front end of the liquid supply pipeline and is used to adjust the mixing ratio of the foaming agent and water. The spray attitude adjustment unit is connected to the spray assembly of the submerged foam generating spray module and is used to adjust the spray angle, swing amplitude, and spray range of the spray assembly.

[0036] This solution, through the setting of adjustment structures corresponding to different parameters, enables independent and synchronous adjustment of the air source, base liquid, and additive ratio during foam generation, as well as the attitude and range of foam spraying. Each adjustment structure can precisely control its corresponding parameter, ensuring that all parameters meet the requirements of the adjustment command. By adjusting the air source pressure and flow rate, the foam generation speed and foaming ratio can be adjusted to adapt to different on-site needs; by adjusting the base liquid output flow rate, the overall foam generation volume can be adjusted to match different coverage requirements; by adjusting the additive mixing ratio, the stability and adhesion performance of the foam can be adjusted, ensuring that the foam maintains an effective working time under different working environments; by adjusting the spraying attitude, the spraying direction and coverage range of the foam can be flexibly adjusted, allowing the foam to accurately cover the area to be treated and avoiding ineffective spraying.

[0037] Specifically, in this embodiment, the submerged foam generating and spraying module includes a multi-channel foam generating unit, an annular spraying frame, and multiple sets of directional spraying components. The annular spraying frame is fixed to the rear end of the cutting section of the roadheader and is arranged around the cutting arm. The input ends of the multi-channel foam generating units are respectively connected to the air source and liquid supply pipeline of the multi-parameter coordinated adjustment module, and the output ends are respectively connected to the annular spraying frame and each directional spraying component. The multiple sets of directional spraying components are respectively arranged on the two sides, roof, and floor of the roadway of the roadway, and cooperate with the annular spraying frame to form a foam spraying network covering the entire cross-section of the roadway. The generated submerged foam fills the entire cross-sectional space of the roadway end, forming a sealed barrier to prevent dust diffusion.

[0038] This solution utilizes a ring-shaped spray structure surrounding the cutting arm to create a continuous spray coverage at the dust source, addressing dust instantly and preventing its outward spread. Directional spray structures are deployed on the sides, roof, and floor of the tunnel, working in conjunction with the ring-shaped spray structure to form a complete spray network across the entire cross-section of the working face. This eliminates blind spots and ensures that the generated foam fills the entire cross-sectional space at the end of the working face, forming a continuous barrier structure to prevent dust from spreading outward from the edges. Multiple independent foam generation structures provide independent foam supply to spray structures at different locations, ensuring that each structure outputs foam according to its adjustment requirements, preventing insufficient supply due to varying needs.

[0039] Specifically, in this embodiment, the main control module also has a built-in closed-loop feedback adjustment unit. The closed-loop feedback adjustment unit receives the concentration data from the global dust concentration monitoring module in real time, compares the measured concentration value after foam adjustment with the preset target concentration value, and when the measured value is higher than the target concentration value, the foam output parameters are gradually increased. When the measured value is lower than the lower limit threshold of the target concentration value, the foam output parameters are gradually decreased, forming a fully closed-loop real-time adjustment link.

[0040] This solution acquires real-time dust-related data after adjustment and compares it with a preset target state. This allows for real-time assessment of the actual effectiveness of the adjustment actions and dynamic adjustments to the parameters based on the actual treatment results. When the treatment effect does not meet expectations, the treatment intensity can be gradually increased to ensure the final treatment effect meets the preset requirements. Conversely, when the treatment effect exceeds the expected reasonable range, the treatment intensity can be gradually reduced to minimize unnecessary resource consumption. This real-time comparison and dynamic adjustment method ensures that the entire system's adjustments always adapt to actual changes on-site, avoiding adjustment failures caused by changes in the on-site environment or equipment status, and guaranteeing a stable and effective treatment effect throughout the entire operation.

[0041] Specifically, in this embodiment, the foaming agent ratio adjustment unit has a built-in concentration closed-loop control subunit. The concentration closed-loop control subunit detects the actual mixing concentration of the foaming agent in the liquid supply pipeline in real time, compares it with the target ratio concentration issued by the main control module, and automatically adjusts the output frequency of the foaming agent metering pump to achieve precise closed-loop adjustment of the foaming agent concentration. At the same time, it adjusts the output of the metering pump synchronously when the liquid supply flow changes to ensure the stability of the ratio concentration.

[0042] This solution accurately obtains the actual mixing state of the additive and base liquid by real-time monitoring of the actual mixing concentration within the pipeline. It compares this to the preset target ratio and adjusts the additive supply based on the comparison results. This ensures that the mixed concentration precisely matches the adjustment requirements, avoiding the inaccuracies and adjustment lags inherent in manual mixing. When the base liquid supply flow rate changes, the additive supply rate is adjusted synchronously, preventing ratio fluctuations caused by changes in base liquid flow rate. This ensures that the mixing concentration remains stable during base liquid flow rate adjustments, preventing significant fluctuations in foam performance and thus guaranteeing the stability of the foam treatment effect.

[0043] Specifically, in this embodiment, the system also includes a fault self-diagnosis redundancy protection module. The fault self-diagnosis redundancy protection module is electrically connected to the main control module, the multi-parameter collaborative adjustment module, and the submerged foam generation and spraying module, respectively. It monitors the gas source pressure, liquid supply pressure, pipeline flow rate, foaming agent level, and operating status of the spraying components in real time. When a blockage of a single spraying component or an abnormal liquid supply is detected, it automatically switches to the backup pipeline, while lowering the output parameters of the faulty loop and raising the foam output parameters of the adjacent loop to ensure the continuity of the full-section submerged dust suppression barrier.

[0044] This solution monitors the operational status of all components of the system, including the gas source, liquid supply, pipelines, and injection structure, in real time. This allows for the timely detection of anomalies and prevents system downtime caused by escalating abnormalities. When a single injection structure or liquid supply pipeline malfunctions, the system automatically switches to a backup supply pipeline, ensuring uninterrupted system operation. Simultaneously, it adjusts the output parameters of the faulty loop and adjacent loops, supplementing the coverage of the faulty loop with the output of adjacent loops. This prevents coverage blind spots caused by single-loop structural failures and ensures the continuous integrity of the barrier structure within the work area, preventing a significant decrease in treatment effectiveness due to localized faults.

[0045] Specifically, in this embodiment, each laser dust detection substation of the global dust concentration monitoring module has an intrinsically safe explosion-proof structure and a sampling frequency of not less than 10Hz. The data collected by each substation is synchronized at the millisecond level through a time synchronization protocol. Based on the synchronized multi-point concentration data, the main control module constructs a real-time distribution model of the dust concentration field of the tunnel boring machine. Based on the distribution model, it locates high-concentration dust-generating areas and adjusts the foam output parameters of the corresponding area spray components in a directional manner.

[0046] This solution, through its explosion-proof structural design adapted to the underground working environment, ensures the safe and stable operation of the data acquisition substation in high-risk underground working environments, preventing safety hazards caused by structural problems in the equipment itself. A high sampling frequency allows for rapid capture of rapid changes in dust concentration within the working face, avoiding missing abrupt changes due to long sampling intervals and ensuring that the collected data reflects the actual situation on site in real time. High-precision time synchronization allows data from different locations to be matched on the same time dimension, providing an accurate data foundation for constructing a complete dust distribution map. The dust distribution model built based on synchronized multi-location data accurately presents the dust distribution at different locations within the working face, precisely locating areas with high dust concentrations. This allows for targeted adjustments to the corresponding spray structure in those areas, making foam supply and coverage more targeted, avoiding resource waste from indiscriminate adjustments to parameters across the entire area, and improving the treatment effect in high-concentration areas.

[0047] Specifically, in this embodiment, the spray attitude adjustment unit has a built-in swing control subunit. The swing control subunit controls the swing frequency and swing angle of the annular spray frame and the directional spray assembly according to the adjustment command issued by the main control module. When the cutting part of the roadheader moves laterally, the spray direction is adjusted in sync with the movement trajectory of the cutting part to ensure that the foam always covers the dust source of the cutting. At the same time, the swing amplitude is adjusted in the dust diffusion area to expand the foam coverage area and enhance the flooding dust suppression effect.

[0048] This solution precisely controls the oscillation of the spraying structure, allowing for flexible adjustment of the spray range and dynamic adaptation of the foam coverage area to changing operational conditions. When the cutting structure of the equipment moves laterally, the spray direction adjusts synchronously to follow its trajectory, ensuring the foam consistently covers the dust source during cutting operations. This addresses dust at its source, preventing gaps in coverage caused by structure movement. In areas where dust has spread, the oscillation amplitude can be adjusted to expand the foam coverage, comprehensively treating the dispersed dust and preventing further spread into the tunnel and personnel work areas, thus enhancing the overall treatment effect.

[0049] Working principle: After deployment and commissioning, the system is started and put into operation simultaneously with the tunneling operation of the roadheader. The dust monitoring structure deployed across the entire face of the roadheader collects real-time dust concentration data from different areas of the face and connects to the roadheader's control system to synchronously acquire the roadheader's real-time operating condition data. The collected concentration data, after time synchronization processing and operating condition calibration, is transmitted to the main control module in real time.

[0050] The main control module integrates and processes the received concentration and operating condition data, and generates corresponding multi-parameter adjustment commands based on preset dust concentration ranges and operating condition matching rules. These commands are then simultaneously sent to the multi-parameter adjustment structure. Upon receiving the adjustment commands, the multi-parameter adjustment structure precisely adjusts multiple parameters, including foaming air pressure, liquid supply flow rate, foaming agent concentration, and spraying posture, and synchronously delivers the adjusted air source and foaming mixture to the foam generation and spraying structure.

[0051] The foam generation and spraying structure receives the regulated gas source and foaming liquid to generate foam with corresponding parameters. Through the ring-shaped spraying structure and directional spraying structure deployed across the entire cross-section, the foam is directionally sprayed into the dust-generating area of ​​the tunnel face, forming a full-section foam barrier at the tunneling end of the tunnel face. This barrier adsorbs and settles the dust generated during the cutting operation, while also preventing the dust from spreading to the area where workers are active and behind the tunnel.

[0052] Throughout the system's operation, the dust monitoring structure continuously collects dust concentration data from various areas of the tunnel face after dust suppression and transmits it back to the main control module in real time. The main control module compares the actual dust concentration data with the preset target state, dynamically corrects the adjustment parameters, and then adjusts the various output parameters of the foam through a multi-parameter adjustment structure, forming a complete closed-loop adjustment link to ensure that the dust suppression effect always meets the on-site protection requirements. At the same time, the system monitors the operating status of each pipeline and component in real time. When an abnormality is detected, it automatically performs redundancy switching and parameter compensation adjustments to ensure that the system can operate continuously and stably in the complex underground environment.

[0053] How to use: 1. Installation and deployment Before use, based on the cross-sectional dimensions of the tunnel face and the model and specifications of the roadheader, corresponding dust monitoring substations should be deployed at various locations on the tunnel face, including the dust source during cutting, the driver's work area, the upwind and downwind entrances on the return air side of the tunnel, and both sides of the tunnel, to ensure that the monitoring range can completely cover the entire cross-sectional area of ​​the tunnel face. A ring-shaped spray structure should be installed at the rear end of the roadheader's cutting section, and directional spray structures should be installed at corresponding locations on the tunnel sides, roof, and floor. The initial installation angle of each spray structure should be adjusted to ensure that the spray range can cover the entire cross-section of the tunnel face without any blind spots. The multi-parameter adjustment structure should be connected to the underground gas source pipeline, water supply pipeline, foaming agent supply device, and each spray structure via pipelines. The main control module should be electrically connected to the dust monitoring structure, the multi-parameter adjustment structure, and the roadheader control system to complete the deployment of the entire system.

[0054] 2. System debugging After deployment, a comprehensive inspection of the entire system's piping and electrical connections is conducted to ensure there are no leaks and wiring errors. Then, the system's power, air, and water supplies are connected, and the system undergoes no-load testing. During testing, based on the on-site operational requirements of the tunnel face, corresponding dust concentration ranges and suitable foam operating parameters are preset. The acquisition accuracy and data synchronization of each monitoring substation are calibrated, the adjustment accuracy and response speed of the multi-parameter adjustment structure are tested, and the spray range and oscillation motion of each spray structure are adjusted to ensure that each component operates normally according to preset requirements. Simultaneously, the system's closed-loop feedback adjustment function and fault protection function are tested. Once all system functions are confirmed to be normal, the system can be put into normal use.

[0055] 3. Daily Operation After the system is put into use, it starts synchronously with the tunneling operation of the roadheader. Upon startup, the dust monitoring structure collects real-time dust concentration data from various areas of the roadheader face, simultaneously acquiring the roadheader's operating condition data and transmitting it to the main control module. Based on the received real-time data, the main control module automatically generates corresponding adjustment commands, controlling the multi-parameter adjustment structure to synchronously adjust various operating parameters of the foam. The foam generation and spraying structure generates foam with corresponding parameters and sprays it into the dust-generating areas of the roadheader face, forming a full-section foam barrier to treat the dust generated during operation.

[0056] During system operation, the system automatically adjusts various operating parameters dynamically based on real-time dust concentration data via a closed-loop feedback adjustment link, eliminating the need for frequent manual intervention. Simultaneously, the system monitors the operating status of each component in real time, automatically performing redundancy switching and parameter compensation in case of pipeline blockages or abnormal liquid supply, ensuring continuous and stable system operation. On-site personnel are only required to conduct periodic inspections.

[0057] 4. Shutdown and Maintenance When the roadheader stops tunneling, the system will automatically lower its operating parameters to standby mode. Once the dust concentration at the tunnel face drops to a preset safe range, the system can be manually shut down. After shutdown, flush the liquid supply lines and spraying mechanisms with clean water to prevent foaming agent residue from clogging the lines or nozzles. During daily use, regularly clean the sampling ports of the monitoring substation, check the foaming agent storage device's liquid level, pipeline seals, and electrical wiring, replace damaged parts promptly, and replenish the foaming agent to ensure the system's continued normal and stable operation.

[0058] 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. A submerged foam control system for tunnel faces based on real-time dust concentration monitoring, characterized in that, It includes a global dust concentration monitoring module, a submerged foam generation and spraying module, a multi-parameter coordinated adjustment module, and a main control module, among which: The full-area dust concentration monitoring module is deployed at full-section measuring points on the tunnel face to collect real-time data on total dust concentration and respirable dust concentration in different areas of the tunnel face, and transmits the collected concentration data to the main control module in real time. The main control module is electrically connected to the global dust concentration monitoring module and the multi-parameter collaborative adjustment module, respectively. It is used to receive concentration data, combine the preset dust concentration threshold with the tunneling face working condition data, generate multi-parameter adjustment instructions, and send the adjustment instructions to the multi-parameter collaborative adjustment module. The multi-parameter coordinated adjustment module is connected to the pipeline and control of the submerged foam generating and spraying module, and is used to receive adjustment commands from the main control module and synchronously adjust the foaming air pressure, liquid supply flow rate, foaming agent concentration and spray coverage parameters of the submerged foam generating and spraying module. The submerged foam generating and spraying module is deployed at the tunneling end of the roadheader and around the entire cross-section of the roadheader face. It is used to receive the adjustment output of the multi-parameter coordinated adjustment module, generate submerged foam with corresponding parameters, and spray it onto the dust-generating area of ​​the roadheader face to form a full-section submerged dust barrier.

2. The submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring according to claim 1, characterized in that, The global dust concentration monitoring module includes multiple sets of laser dust detection substations, a data acquisition and transmission unit, and a working condition linkage calibration unit. The multiple sets of laser dust detection substations are respectively deployed at the cutting end of the roadheader, the roadheader operator's operating position, the upper air outlet of the return air side of the roadheader face, the lower air outlet of the return air side, and the two sides of the roadway of the roadheader face, to collect total dust and respirable dust concentration data from the dust source, the personnel working area, and the roadway diffusion area. The data acquisition and transmission unit transmits the concentration data from each substation to the main control module after time synchronization processing; the working condition linkage calibration unit collects the cutting motor operating current and travel speed data of the roadheader, and performs dynamic calibration on the concentration data to eliminate the interference of tunneling operation vibration on the detection accuracy.

3. The submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring according to claim 1, characterized in that, The main control module has a built-in dust concentration grading control unit and a working condition matching unit. The dust concentration grading control unit has multiple preset dust concentration threshold ranges that increase step by step, and matches the corresponding foam control parameter set for different concentration threshold ranges. The working condition matching unit is connected to the control system of the roadheader and obtains the working condition data of the roadheader's cutting, traveling, stopping, and spraying operations in real time. It dynamically corrects the adjustment commands based on the concentration data, increases the foam coverage intensity when the roadheader is cutting, and lowers the foam output parameters to the standby threshold when the roadheader is stopped.

4. The submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring according to claim 1, characterized in that, The multi-parameter coordinated adjustment module includes an air pressure adjustment unit, a liquid supply adjustment unit, a foaming agent ratio adjustment unit, and a spray attitude adjustment unit. The air pressure adjustment unit is connected to the air source pipeline of the submerged foam generating spray module and is used to adjust the output pressure and flow rate of the foaming air source. The liquid supply adjustment unit is connected to the liquid supply pipeline of the submerged foam generating spray module and is used to adjust the output flow rate of the foaming base liquid. The foaming agent ratio adjustment unit is connected in series at the front end of the liquid supply pipeline and is used to adjust the mixing ratio of the foaming agent and water. The spray attitude adjustment unit is connected to the spray assembly of the submerged foam generating spray module and is used to adjust the spray angle, swing amplitude and spray range of the spray assembly.

5. The submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring according to claim 1, characterized in that, The submerged foam generating and spraying module includes a multi-channel foam generating unit, a ring spraying frame, and multiple sets of directional spraying components; the ring spraying frame is fixed to the rear end of the cutting section of the roadheader and is arranged around the cutting arm. The input end of the multi-channel foam generating unit is connected to the air source and liquid supply pipeline of the multi-parameter coordinated adjustment module, and the output end is connected to the annular spray frame and each directional spray component. Multiple sets of directional spray components are respectively arranged on the two sides, roof and floor of the tunnel face, and together with the annular spray frame, they form a foam spray network covering the entire cross section of the tunnel face. The generated submerged foam fills the entire cross section space at the tunneling end of the tunnel face, forming a sealed barrier to prevent dust diffusion.

6. The submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring according to claim 1, characterized in that, The main control module also has a built-in closed-loop feedback adjustment unit. The closed-loop feedback adjustment unit receives the concentration data from the global dust concentration monitoring module in real time, compares the measured concentration value after foam adjustment with the preset target concentration value, and gradually increases the foam output parameters when the measured value is higher than the target concentration value. When the measured value is lower than the lower limit threshold of the target concentration value, it gradually decreases the foam output parameters, forming a fully closed-loop real-time adjustment link.

7. The submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring according to claim 4, characterized in that, The foaming agent ratio adjustment unit has a built-in concentration closed-loop control subunit. The concentration closed-loop control subunit detects the actual mixing concentration of the foaming agent in the liquid supply pipeline in real time, compares it with the target ratio concentration issued by the main control module, and automatically adjusts the output frequency of the foaming agent metering pump to achieve precise closed-loop adjustment of the foaming agent concentration. At the same time, it adjusts the output of the metering pump synchronously when the liquid supply flow changes to ensure the stability of the ratio concentration.

8. The submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring according to claim 1, characterized in that, The system also includes a fault self-diagnosis redundancy protection module, which is electrically connected to the main control module, the multi-parameter collaborative adjustment module, and the submerged foam generating and spraying module. It monitors the gas source pressure, liquid supply pressure, pipeline flow, foaming agent level, and operating status of the spraying components in real time. When a blockage of a single spraying component or an abnormal liquid supply is detected, it automatically switches to the backup pipeline, lowers the output parameters of the faulty loop, and raises the foam output parameters of the adjacent loop to ensure the continuity of the full-section submerged dust suppression barrier.

9. The submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring according to claim 2, characterized in that, Each laser dust detection substation of the global dust concentration monitoring module has an intrinsically safe explosion-proof structure and a sampling frequency of not less than 10Hz. The data collected by each substation is synchronized at the millisecond level through a time synchronization protocol. Based on the synchronized multi-point concentration data, the main control module constructs a real-time distribution model of the dust concentration field of the tunneling face, locates high-concentration dust-generating areas based on the distribution model, and adjusts the foam output parameters of the corresponding area spray components in a directional manner.

10. The submerged foam conditioning system for tunnel faces based on real-time dust concentration monitoring according to claim 4, characterized in that, The spray attitude adjustment unit has a built-in swing control subunit. According to the adjustment command issued by the main control module, the swing control subunit controls the swing frequency and swing angle of the ring spray frame and the directional spray component. When the cutting part of the roadheader moves laterally, the spray direction is adjusted in sync with the movement trajectory of the cutting part to ensure that the foam always covers the dust source of the cutting. At the same time, the swing amplitude is adjusted in the dust diffusion area to expand the foam coverage area and enhance the flooding dust suppression effect.

Images