A working method and system of a hydraulic support digital twin system

Abstract

The application provides a working method and system of a hydraulic support digital twin system, and relates to the technical field of industrial equipment digitization and intelligentization, to solve the technical problems of insufficient fidelity caused by rigid assumptions of simulation models, difficulty in deep coupling of multidisciplinary models, and lack of virtual-real closed-loop interaction mechanism in related technologies. The method comprises the following steps: constructing an electro-hydraulic coupling dynamics model; constructing a digital twin visualization body; and performing virtual-real closed-loop interaction.

Description

Technical Field

[0001] This application relates to the field of digital and intelligent technology of industrial equipment, and in particular to a working method and system of a hydraulic support digital twin system. Background Technology

[0002] Hydraulic supports, as the core support equipment in fully mechanized mining faces, directly affect the safety and efficiency of coal mine production. Currently, the research and optimization of hydraulic supports mainly rely on physical prototype testing or computer simulation analysis based on isolated physical fields. However, existing simulation technologies often simplify the key components of hydraulic supports as rigid bodies, ignoring the impact of elastic deformation of components on system performance under high load conditions, resulting in insufficient model fidelity. Furthermore, existing simulation systems often struggle to achieve deep coupling between mechanical, hydraulic, and electrical control systems, and lack a two-way closed-loop interaction mechanism based on real-time data between physical entities and virtual models. This makes it impossible to achieve high-precision synchronous mapping and dynamic verification of physical states in a 3D visualization environment, failing to meet the intelligent operation and maintenance needs under complex working conditions. Summary of the Invention

[0003] To address the aforementioned technical problems, this application provides a working method, system, equipment, and medium for a hydraulic support digital twin system, thereby resolving the technical issues in related technologies, such as insufficient fidelity due to rigid assumptions in simulation models, difficulty in deep coupling of multidisciplinary models, and lack of a virtual-real closed-loop interaction mechanism.

[0004] In a first aspect, the embodiments of this specification provide a method for operating a hydraulic support digital twin system, the system including a simulation calculation module and a visualization interaction module with data communication connection; the method includes: Construct an electromechanical-hydraulic coupled dynamic model: Obtain flexible body characteristic data of key load-bearing components of hydraulic supports, combine the dynamic model of hydraulic system with the logic model of electro-control system, and integrate and generate a high-fidelity dynamic model that can respond to control commands and output dynamic states in the simulation calculation module; Constructing a digital twin visualization: Create a 3D scene of the hydraulic support and its working environment, configure physical attributes and motion logic, and generate a digital twin that is geometrically mapped to the physical entity in the visualization interaction module; Perform virtual-real closed-loop interaction: Receive real-time sensing data from the physical hydraulic support through the data communication interface, drive the digital twin to synchronize its position and posture, and simultaneously map the real-time sensing data into input parameters and transmit them to the simulation calculation module. Trigger the high-fidelity dynamic model to perform real-time calculation, and feed back the dynamic parameters generated by the calculation to the visualization interaction module for status monitoring or verification.

[0005] This solution employs a server-client collaborative architecture to construct a complete closed-loop system encompassing electromechanical-hydraulic coupling and 3D visualization. By acquiring the flexible characteristics of key components and combining them with electromechanical-hydraulic models, it overcomes the limitations of traditional rigid body simulation, achieving high-fidelity dynamic simulation. Simultaneously, a digital twin geometrically mapped to the physical entity is established, and pose synchronization is driven by real-time sensor data, ensuring consistency between the virtual environment and real-world working conditions. Furthermore, by utilizing real-time calculated dynamic parameter feedback, bidirectional data flow and closed-loop verification are achieved from the physical entity to the digital twin, and then to the high-fidelity simulation model, providing a precise digital platform for hydraulic support condition monitoring, performance evaluation, and control strategy optimization.

[0006] In one implementation, an electromechanical-hydraulic coupled dynamic model is constructed, including the following steps for constructing a flexible column: finite element discretization is performed on key load-bearing components, material properties and connection boundaries are defined, and modal parameters in the free state are calculated to generate a flexible body description file.

[0007] This approach utilizes finite element analysis (FEM) technology to obtain the modal characteristics of key components (such as columns), breaking the limitation of treating load-bearing components as absolutely rigid bodies in traditional simulations. The generated flexible body description file can accurately describe the minute elastic deformations of the components under complex conditions such as impact pressure, thus more realistically reflecting the force transmission path and energy absorption within the support structure. This provides a data foundation that conforms to objective physical laws for the subsequent construction of a high-fidelity dynamic model.

[0008] In one implementation, the construction of the electromechanical-hydraulic coupled dynamic model also includes a system function analysis step: constructing a parameterized hydraulic circuit model containing pumps, valves and actuators based on a hydraulic component library; calling a hydraulic medium model library to establish a temperature-viscosity relationship model to define the physical properties of the working medium; constructing a controller function model based on a state flow diagram; and verifying the control strategy logic of the controller function model through step response and frequency response analysis methods.

[0009] This solution achieves refined modeling and verification at the subsystem level. On one hand, by establishing a temperature-viscosity relationship model, the physical properties of hydraulic oil at different operating temperatures are accurately defined, solving the calculation deviation caused by the neglect of changes in medium properties in traditional models. On the other hand, through step response and frequency response analysis, the logic verification of the control strategy is completed before integration, ensuring the accuracy of the electronic control model's response to commands such as initial support and frame movement, thereby guaranteeing the high precision and high reliability of each subsystem model.

[0010] In one implementation, the construction of the electromechanical-hydraulic coupled dynamic model further includes a high-fidelity model integration step: importing the flexible body description file into the multibody system dynamics environment, replacing the corresponding rigid components, and using node mapping technology to establish the mechanical transmission relationship between the flexible body and adjacent components; and coupling and integrating the parameterized hydraulic circuit model, the controller function model, and the multibody system model containing the flexible body through a defined signal flow interface.

[0011] This solution addresses the challenge of deep integration of multidisciplinary models. Node mapping technology ensures the continuity and accuracy of mechanical transmission between flexible bodies (such as movable columns) and rigid components (such as top beams and bases). More importantly, by using a signal flow interface, models from the mechanical, hydraulic, and electrical control domains are integrated, enabling real-time data interaction and native coupling. This allows the final dynamic model to comprehensively and realistically simulate the dynamic behavior of hydraulic supports under complex electromechanical-hydraulic coupling.

[0012] In one implementation, the key load-bearing components are discretized using finite element methods, specifically including: The geometric model of key load-bearing components is simplified and repaired. Establish remote points at the assembly interface and set degree-of-freedom constraints and mechanical correlation areas according to the actual connection type; Configure the modal extraction order and damping parameters, and solve to generate a standard modal neutral file containing the mass matrix, stiffness matrix and mode shapes.

[0013] This scheme standardizes a refined process for constructing flexible bodies. Mesh quality is optimized through feature simplification and repair, improving analysis efficiency while maintaining computational accuracy. By establishing remote points and setting accurate degree-of-freedom constraints, the accurate mechanical transmission relationships of the flexible body within the assembly are ensured. Finally, a standard neutral file containing complete modal information is generated, enabling seamless integration of finite element analysis results into multibody dynamics systems, laying a solid foundation for high-fidelity system-level simulations.

[0014] In one implementation, the virtual-real closed-loop interaction process further includes: A high-fidelity dynamic model is solved using a variable step-size integral algorithm; Based on the flexible body description file integrated in the model, stress recovery technology is used to calculate and output the stress distribution and deformation state of key load-bearing components in real time.

[0015] This scheme utilizes a variable-step integration algorithm to ensure the numerical stability and computational accuracy of the electromechanical-hydraulic coupled system during the solution process. More importantly, by combining stress recovery technology, it is possible to invert the stress distribution and deformation of key components in real time during the simulation, filling the gap in traditional rigid body simulation that cannot directly assess structural strength. This provides direct data support for fatigue life assessment and safety early warning of hydraulic supports under extreme working conditions.

[0016] In one implementation, constructing a digital twin visualization includes: Construct a three-dimensional model of the hydraulic support, conveying equipment, and the roof coal seam and its collision bodies, and establish the parent-child hierarchical relationship between the components; Add rigid body components to the 3D model and set mass and friction coefficient parameters; establish the kinematic logic of the support based on the finite state machine, and define the work cycle action rules including column lowering, support shifting, column raising and sliding to control the motion response of the virtual components.

[0017] This solution constructs a high-precision 3D scene encompassing equipment and the environment, and achieves visual reconstruction of physical entities through parent-child hierarchical relationships and physical attribute configuration. By introducing finite state machine technology to establish kinematic logic, the digital twin not only possesses visual similarity but also behavioral logic consistent with actual process flows. It can accurately simulate complex action sequences such as column lowering and frame shifting, enhancing the logic and interactivity of the virtual demonstration.

[0018] In one implementation, performing a virtual-real closed-loop interaction specifically includes: The visualization and interaction module analyzes the pose and load data of the physical hydraulic support and uses an interpolation algorithm to drive the digital twin to update its visual state. The initial state parameters extracted from the analysis are encoded with the action instructions and sent to the simulation calculation module via a network protocol; The simulation calculation module performs simulations based on received instructions, providing real-time feedback on calculation results, including column pressure, displacement, and hydraulic system status, which are presented in a multimodal format in the visualization interaction module. This solution establishes an efficient two-way data transmission mechanism. Interpolation algorithms are used to ensure the smoothness and real-time performance of the visualized model's movements. By accurately transmitting the physical state to the simulation end through network protocols, the initial boundary conditions of the simulation calculation are consistent with reality. Finally, the multi-dimensional data such as pressure and displacement obtained from the simulation are presented on the front end in a multi-modal form (such as curves and animations), realizing "virtual and real data fusion display", which greatly improves the user's ability to perceive the operating status of the equipment.

[0019] In one implementation, the method further includes: The measured data of the physical hydraulic support are compared and analyzed in real time with the dynamic parameters fed back by the simulation calculation module. The accuracy of the high-fidelity dynamic model is verified according to the error evaluation index.

[0020] This solution establishes an online verification closed loop. By comparing physical measurement data with simulation calculation data in real time, the predictive accuracy of the high-fidelity model can be quantitatively evaluated, and model deviations can be detected in a timely manner. This not only verifies the reliability of the digital twin system but also provides an objective basis for subsequent model correction and optimization, achieving continuous improvement in system accuracy.

[0021] Secondly, this specification provides a hydraulic support digital twin system, comprising: The electromechanical-hydraulic coupling modeling unit is used to construct a high-fidelity dynamic model that integrates the flexible characteristics of key load-bearing components, hydraulic dynamic characteristics, and electronic control logic. Virtual twin building blocks are used to construct digital twins of hydraulic supports with physical attributes, collision detection, and motion logic control. The closed-loop interactive control unit is used to connect the physical hydraulic support, high-fidelity dynamic model and digital twin through a bidirectional data link to realize real-time state mapping drive and simulation data feedback.

[0022] This solution uses a modular unit design to decouple the complex digital twin system into three core functional areas: modeling, construction, and interaction, resulting in a clear structure.

[0023] The electromechanical-hydraulic coupling modeling unit ensures the depth and accuracy of the simulation, the virtual twin building unit provides an intuitive visualization environment, and the closed-loop interactive control unit opens up the data link. The three work together to realize the state perception and intelligent operation and maintenance of the hydraulic support throughout its entire life cycle.

[0024] Thirdly, embodiments of this specification provide an electronic device including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the method as described in any of the first aspects.

[0025] Fourthly, embodiments of this specification provide a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the method as described in any of the first aspects. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0027] Figure 1 A flowchart illustrating the operation of a hydraulic support digital twin system provided for embodiments of this specification; Figure 2 This is a technology roadmap for a digital twin closed-loop system for hydraulic supports based on a multidisciplinary high-fidelity model. Figure 3 Flowchart of the server side of the digital twin closed-loop system for hydraulic supports; Figure 4 Flowchart for the construction and integration of flexible bodies; Figure 5 A diagram illustrating the bidirectional data link interaction of a digital twin closed-loop system for hydraulic supports. Figure 6 Flowchart of the client-side process for the digital twin closed-loop system of hydraulic supports; Figure 7 A schematic diagram of the working system of a hydraulic support digital twin system provided for the implementation of this specification; Figure 8 This is a schematic diagram of the structure of an electronic device provided for the implementation of this specification. Detailed Implementation

[0028] Unless otherwise defined, the technical or scientific terms used in the embodiments of this specification shall have the ordinary meaning understood by one skilled in the art to which this specification pertains. The terms "first," "second," and similar terms used in the embodiments of this specification do not indicate any order, quantity, or importance, but are merely used to avoid confusion of constituent elements.

[0029] Unless the context otherwise requires, throughout this specification, "a plurality of" means "at least two," and "including" is interpreted as open-ended or encompassing, that is, "including, but not limited to." In the description of this specification, terms such as "one embodiment," "some embodiments," "exemplary embodiment," "example," "specific example," or "some examples" are intended to indicate that a particular feature, structure, material, or characteristic associated with that embodiment or example is included in at least one embodiment or example of this specification. The illustrative representations of the above terms do not necessarily refer to the same embodiment or example.

[0030] The technical solutions in the embodiments of this specification will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this specification, and not all embodiments. Based on the embodiments in this specification, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this specification.

[0031] As mentioned in the background section, hydraulic supports are the core support equipment for fully mechanized mining faces, and their performance directly affects the safety and efficiency of coal mine production. With the development of intelligent manufacturing technology, higher requirements are being placed on the accurate modeling and full lifecycle status perception of production equipment. Traditional hydraulic support design and optimization methods mainly rely on physical prototype testing or computer-aided engineering analysis based on a single physical field, which suffers from problems such as isolated models, high testing costs, and long testing cycles.

[0032] While technological advancements have led to the emergence of some simulation systems based on hardware-in-the-loop or automatic follow-up control, significant limitations remain. Firstly, existing dynamic simulations largely rely on rigid body assumptions to build models, lacking rigid-flexible coupling mechanisms. This prevents the accurate simulation of the flexible deformation effects of critical load-bearing components like columns under extreme loads such as rockbursts, resulting in deviations in structural stress distribution analysis and fatigue life assessment, and insufficient model fidelity. Secondly, current technologies suffer from insufficient system integration, often focusing on a specific area (such as simple hydraulic control or mechanical motion) and failing to effectively achieve deep integration of mechanical dynamics, hydraulic transmission, and electronic control logic across multiple disciplines. Furthermore, current systems often lack real-time bidirectional data interaction capabilities between physical entities and digital twins. Control strategies often depend on preset programs rather than real-time operational condition analysis, hindering the construction of high-precision visualization systems capable of real-time mapping of physical states and synchronous closed-loop verification. This limits their response speed and decision-making accuracy in complex coal seam environments.

[0033] Based on the above inventive concept, the working method of the hydraulic support digital twin system provided in the embodiments of this specification will be described exemplarily below.

[0034] This specification provides a method for operating a hydraulic support digital twin system, such as... Figure 1 As shown, it includes: S101. Construct an electromechanical-hydraulic coupling dynamic model.

[0035] In practice, the flexible body characteristic data of the key load-bearing components of the hydraulic support are obtained. Combined with the dynamic model of the hydraulic system and the logic model of the electronic control system, a high-fidelity dynamic model that can respond to control commands and output dynamic states is generated in the simulation calculation module.

[0036] This step aims to generate a high-fidelity single-frame dynamic model. This process is executed on the server side and includes the following three core sub-steps: 1. Flexible Column Construction Steps: This step is primarily performed in finite element analysis software (such as ANSYS). First, the geometric model of the key load-bearing components of the hydraulic support (such as the piston column) is obtained, and features are simplified and repaired to remove small-scale features that do not affect the overall stiffness (such as chamfers and bolt holes). Second, finite element discretization is performed, material properties (elastic modulus, Poisson's ratio, etc.) are defined, and remote points are established at the component assembly interface. Freedom constraints are set according to the actual connection type (pin connection or fixed connection). Next, flexible configuration is performed using the APDL command flow, setting the modal extraction order and damping parameters. Finally, modal analysis is performed to calculate the natural frequencies and mode shapes of the component in the free state, generating a standard modal neutral file (.mnf) containing the mass matrix, stiffness matrix, mode shapes, and nodal masses.

[0037] 2. System Functional Analysis Steps: This step relies on a multi-domain modeling platform (such as MWORKS.Sysplorer). On one hand, for the hydraulic system, a parametric hydraulic circuit model including pumps, valves, hydraulic cylinders, and pipelines is constructed based on a hydraulic component library. Specifically, to improve the model's adaptability under different operating conditions, a temperature-viscosity relationship model is established using a hydraulic medium model library to accurately define the physical properties of the working medium at different temperatures. On the other hand, for the electronic control system, a controller functional model based on a state flow diagram is constructed. Step response and frequency response analysis methods are used to verify the correctness and dynamic response characteristics of the control strategies (such as initial support and frame shifting logic) before integration.

[0038] 3. High-Fidelity Model Integration Steps: This step involves the multidisciplinary integration of the above results. First, the hydraulic support assembly is imported into the multibody system dynamics environment, defining kinematic pair constraints and load boundaries. Then, the generated flexible body description file (.mnf) is imported, replacing the rigid pistons in the system with flexible body models. During this process, node mapping technology is used to establish the mechanical transmission relationship between the flexible body interface points and adjacent rigid components (such as top beams and bases), ensuring the continuity of force at the connections. Finally, through the defined signal flow interface, the parametric hydraulic circuit model, the controller function model, and the multibody system model containing the flexible body are natively coupled to form a complete electromechanical-hydraulic coupled dynamic model.

[0039] like Figure 2As shown, this embodiment proposes a technical approach for a closed-loop digital twin system for hydraulic supports based on a multidisciplinary high-fidelity model. The system adopts a server-client collaborative architecture, encompassing two core components: an electromechanical-hydraulic coupling module (server) and a virtual environment and twin construction module (client). Regarding the core construction process of the server, as follows... Figure 3 As shown, the electromechanical-hydraulic coupling module mainly consists of three parts: a flexible column construction submodule, a system function analysis submodule, and a high-fidelity model construction and integration submodule. The data flow between the submodules is clear: the flexible column construction submodule outputs modal files, the system function analysis submodule provides hydraulic and electro-control parameters, and the two are combined into the integration submodule to finally generate a high-fidelity hydraulic support dynamic model.

[0040] Specifically, the three sub-stages of the above construction process will be explained in detail: the first is the construction of the flexible column, such as... Figure 4 As shown, this submodule executes in finite element analysis software such as ANSYS. The construction process includes: first, geometric model preprocessing and feature simplification to optimize the topology; then, defining material properties (such as elastic modulus and Poisson's ratio); next, meshing and defining remote points at assembly interfaces; then, performing flexibility-specific settings via APDL command flow; finally, performing modal analysis to generate a standard modal neutral file (.mnf) containing the mass matrix, stiffness matrix, and mode shapes, completing the export of the flexible body file. Its system functions are referenced... Figure 3The system function analysis module, relying on the MWORKS.Sysplorer platform, utilizes a professional model library to construct parametric dynamic models of pumps, valves, and hydraulic cylinders (hydraulic power function analysis), and simultaneously constructs a controller function model (electronic control logic function analysis) to achieve logic verification of "electronic control-hydraulic drive". In finite element analysis software (such as ANSYS), the piston component of the hydraulic support is finely modeled. A partitioned surface size adjustment strategy is implemented to refine the local mesh of complex geometric regions, including importing and simplifying the geometric model, defining material mechanical properties, creating remote points at connections and constraining degrees of freedom (releasing rotational degrees of freedom for pin connections and constraining all degrees of freedom for fixed connections), and mesh generation. Subsequently, flexible configuration is performed through APDL command flow, and modal analysis is executed, generating a standard modal neutral file (.mnf) containing a mass matrix, stiffness matrix, and mode shapes to describe the flexible characteristics of the component. Secondly, system function analysis is performed. Relying on a multi-domain modeling platform (such as MWORKS.Sysplorer), parametric dynamic models of pumps, valves, and hydraulic cylinders are constructed using a professional model library, defining the physical properties of the hydraulic medium. A temperature-viscosity relationship model is established to accurately reflect the physical properties of the working medium under different working conditions. Simultaneously, a controller functional model is constructed to verify the logical correctness and dynamic response characteristics of the control strategy, and to clarify the interface mapping relationship between the hydraulic and electronic control systems. Finally, high-fidelity model construction and integration are performed. A 3D model of the multibody system is imported, and kinematic pairs and load boundaries are defined. Modal neutral files are used to replace rigid components in the system with flexible body models. During this process, node mapping technology is used to ensure the accurate establishment of the mechanical transmission relationship between the flexible body and the interface points of adjacent components. A rigid-flexible coupling topology model of the hydraulic support is constructed in the multibody dynamics environment. The system imports assemblies of components such as the top beam, shield beam, front link, rear link, and base, and defines kinematic constraints such as revolute and prism joints. Specifically, to overcome the limitations of traditional rigid models, this embodiment utilizes the aforementioned generated modal neutral file to perform flexible body replacement. It connects to rigid components (such as the cylinder body, top beam, etc.) through interface points. This "rigid-flexible coupling" structure can realistically simulate the elastic deformation of the support under load. Based on this, through defined signal flows and physical connections, the hydraulic system model, the electro-control system model, and the multibody dynamics model containing flexible bodies are deeply coupled and integrated to form a complete electromechanical-hydraulic system simulation model.

[0041] S102. Construct a digital twin visualization.

[0042] In practice, a three-dimensional scene of the hydraulic support and its working environment is created, physical attributes and motion logic are configured, and a digital twin that is geometrically mapped to the physical entity is generated in the visualization interaction module.

[0043] like Figure 5 As shown, the client's virtual environment and twin construction module process mainly covers three levels: First, the rendering of the 3D visualization scene and high-precision model involves the construction of hydraulic supports, scraper conveyors, and roof coal seam models and the establishment of parent-child relationships; second, the assignment of physical properties and behavioral logic, including the addition of rigid body components, mesh colliders, and the kinematic model of the supports developed based on C# scripts; and finally, the data interface and communication configuration, which is built through System.IO.Ports.SerialPort serial communication and ROS communication to achieve bidirectional connection with physical devices and the server.

[0044] Specifically, the process begins with 3D visualization and high-precision model rendering. The 3D models of equipment such as hydraulic supports and scraper conveyors are converted to a specific format (e.g., FBX) and imported into a 3D engine (e.g., Unity3D). The parent-child hierarchical relationships between components are clearly defined, and a mesh collider is constructed specifically for the roof coal seam to achieve accurate physical interference detection. Simultaneously, collision detection parameters are set to adapt to the contact response under actual working conditions. Next, physical properties and behavioral logic are assigned. Rigid body components and mesh colliders are added to the hydraulic supports, and parameters such as mass and friction coefficient are set. A finite state machine-based kinematic model of the supports is developed using a scripting language (e.g., C#), defining the working cycle logic for column lowering, support shifting, column raising, and conveyor pushing, establishing a behavioral rule system consistent with the real equipment. Finally, data interfaces and communication configurations are implemented. A network connection is built using the ROS communication framework, and physical information is obtained through System.IO.Ports.SerialPort serial communication. A bidirectional real-time transmission interface for control commands and dynamic parameters is configured through a custom data exchange protocol, laying the foundation for virtual-real interaction.

[0045] S103, Execute virtual-real closed-loop interaction.

[0046] In practice, real-time sensing data of the physical hydraulic support is received through the data communication interface, driving the digital twin to synchronize its position and posture. At the same time, the real-time sensing data is mapped into input parameters and transmitted to the simulation calculation module, triggering the high-fidelity dynamic model to perform real-time calculations. The dynamic parameters generated by the calculations are then fed back to the visualization interaction module for status monitoring or verification.

[0047] like Figure 6As shown, the virtual-real interaction and verification process demonstrates the data closed loop between the server (running online), the client, and the hydraulic support test bench. During the interaction, the client first processes the pose sensing data and top beam load data from the test bench through data parsing and feature extraction, directly driving the digital twin model to achieve "real-time mapping of the digital twin state".

[0048] Specifically, during the interaction, the client acquires high-precision tilt and pressure sensor data from the hydraulic support test bench via serial communication (e.g., System.IO.Ports.SerialPort). Digital filtering algorithms are used for data preprocessing, followed by parsing and feature extraction. An interpolation algorithm then directly drives the digital twin model to synchronize state updates, achieving real-time mapping of the physical entity's pose. Simultaneously, the extracted initial state parameters and action command codes are transmitted to the server's simulation module via the ROS communication protocol. The server, based on a high-fidelity single-frame dynamic model, performs electromechanical-hydraulic coupling dynamic simulation using a variable-step integral algorithm. This algorithm ensures numerical stability, and stress recovery technology is used to calculate the stress distribution of key components based on an integrated flexible body model. Fatigue life assessment is also performed. Finally, the simulated parameters, such as column pressure, displacement, and hydraulic system status, are fed back to the client. These are presented through multimodal result visualization (e.g., graphs, 3D animations), and statistical analysis methods are used to compare and analyze the data in real time with measured data. Quantitative verification of system accuracy is completed based on error evaluation indicators.

[0049] In one exemplary embodiment of this specification, a hydraulic support digital twin system 700 is also provided, such as... Figure 7 As shown, it includes: The electromechanical-hydraulic coupling modeling unit 701 is used to construct a high-fidelity dynamic model that integrates the flexible characteristics of key load-bearing components, hydraulic dynamic characteristics, and electronic control logic. Virtual twin building unit 702 is used to build a digital twin of a hydraulic support with physical attributes, collision detection, and motion logic control; The closed-loop interactive control unit 703 is used to connect the physical hydraulic support, high-fidelity dynamic model and digital twin through a bidirectional data link to realize real-time state mapping drive and simulation data feedback.

[0050] Specifically, the electromechanical-hydraulic coupling modeling unit 701 is configured to execute a processing flow including flexible body component construction, system function analysis, and high-fidelity model integration, capable of generating a single-frame dynamic model containing complete flexible body characteristics, hydraulic system dynamic characteristics, and control logic. Its specific configuration includes: generating a flexible body modal neutral file using finite element analysis; replacing rigid components in a multibody system using node mapping technology; and integrating a hydraulic model with temperature-viscosity characteristics and an electro-control logic model, achieving native coupling across multiple disciplines.

[0051] The virtual twin building unit 702 is configured to build a hydraulic support and working environment model in a 3D visualization environment (such as Unity3D), implement logical control of actions such as column lifting and lowering, and side panel extension and retraction through a finite state machine, and construct a digital twin that supports the interaction between the hydraulic support and the coal seam. Specifically, it constructs a scene of a coal seam with a Mesh collider roof in a 3D visualization environment, implements logical control of support actions through a finite state machine, and constructs a digital twin that supports high-intensity interaction.

[0052] The closed-loop interactive control unit 703 is configured to establish a collaborative architecture between the server and the client. On the one hand, it uses the collected sensor data to drive the digital twin to achieve virtual-real synchronization. On the other hand, it transmits physical parameters to a high-fidelity model for simulation calculations and feeds back the calculated dynamic parameters such as column stress and deformation to the visualization terminal for real-time monitoring and virtual-real data verification. Specifically, it performs digital filtering and feature extraction on the collected physical sensor data, drives the twin synchronization, transmits the data to the simulation model for variable-step integral solving and stress recovery calculations, and finally completes virtual-real verification based on error evaluation indicators.

[0053] In one exemplary embodiment of this specification, an electronic device is also provided, such as Figure 8 As shown, the electronic device may include: a processor 310, a communications interface 320, a memory 330, and a communication bus 340, wherein the processor 310, the communications interface 320, and the memory 330 communicate with each other via the communication bus 340. The processor 310 can call logical instructions in the memory 330 to execute the operating method of the hydraulic support digital twin system, the method including: Construct an electromechanical-hydraulic coupled dynamic model: Obtain flexible body characteristic data of key load-bearing components of the hydraulic support, combine the dynamic model of the hydraulic system with the logic model of the electronic control system, and integrate and generate a high-fidelity dynamic model that can respond to control commands and output dynamic states in the simulation calculation module; Constructing a digital twin visualization: Establish a three-dimensional scene of the hydraulic support and its working environment, configure physical attributes and motion logic, and generate a digital twin that is geometrically mapped to the physical entity in the visualization interaction module; Perform virtual-real closed-loop interaction: Receive real-time sensing data of the physical hydraulic support through the data communication interface, drive the digital twin to synchronize its position and posture, and simultaneously map the real-time sensing data into input parameters and transmit them to the simulation calculation module, triggering the high-fidelity dynamic model to perform real-time calculation, and feeding back the calculated dynamic parameters to the visualization interaction module for status monitoring or verification.

[0054] Furthermore, the logical instructions in the aforementioned memory 330 can be implemented as software functional units and, when sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, essentially, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0055] In addition to the methods, apparatus, and devices described above, the operating method of the hydraulic support digital twin system provided in the embodiments of this specification can also be a computer program product, which includes computer program instructions that, when executed by a processor, cause the processor to perform the steps in the operating method of the hydraulic support digital twin system according to various embodiments of this specification as described in the "Exemplary Methods" section above.

[0056] The computer program product can be written in any combination of one or more programming languages ​​to perform the operations of the embodiments of this specification. The programming languages ​​include object-oriented programming languages ​​such as Java and C++, as well as conventional procedural programming languages ​​such as the "C" language or similar programming languages.

[0057] Furthermore, embodiments of this specification also provide a computer-readable storage medium having a computer program stored thereon, the computer program being executed by a processor of the steps in the method of operating a hydraulic support digital twin system according to various embodiments of this specification as described in the "Exemplary Methods" section above.

[0058] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When executed, the computer program can include the processes of the embodiments of the above methods. Any references to memory, storage, databases, or other media used in the embodiments provided in this specification can include non-volatile and / or volatile memory. Non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory may include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM is available in a variety of forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), dual data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link DRAM (SLDRAM), RAMbus direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), etc.

[0059] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0060] The embodiments described above are merely illustrative of several implementation methods outlined in this specification. While the descriptions are specific and detailed, they should not be construed as limiting the scope of the solutions provided in this specification. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this specification, and these all fall within the scope of protection of this specification. Therefore, the scope of protection for this patent should be determined by the appended claims.

Claims

1. A method for operating a digital twin system for a hydraulic support, characterized in that, The system includes a simulation calculation module and a visualization interaction module with data communication connection; the method includes: Construct an electromechanical-hydraulic coupled dynamic model: Obtain flexible body characteristic data of key load-bearing components of the hydraulic support, combine the dynamic model of the hydraulic system with the logic model of the electronic control system, and integrate and generate a high-fidelity dynamic model that can respond to control commands and output dynamic states in the simulation calculation module; Constructing a digital twin visualization: Establish a three-dimensional scene of the hydraulic support and its working environment, configure physical attributes and motion logic, and generate a digital twin that is geometrically mapped to the physical entity in the visualization interaction module; Perform virtual-real closed-loop interaction: Receive real-time sensing data of the physical hydraulic support through the data communication interface, drive the digital twin to synchronize its position and posture, and simultaneously map the real-time sensing data into input parameters and transmit them to the simulation calculation module, triggering the high-fidelity dynamic model to perform real-time calculation, and feeding back the calculated dynamic parameters to the visualization interaction module for status monitoring or verification.

2. The method according to claim 1, characterized in that, The construction of the electromechanical-hydraulic coupled dynamic model includes the following steps: constructing a flexible column: performing finite element discretization on the key load-bearing component, defining material properties and connection boundaries, and calculating modal parameters in the free state to generate a flexible body description file.

3. The method according to claim 2, characterized in that, The construction of the electromechanical-hydraulic coupled dynamic model also includes system function analysis steps: constructing a parameterized hydraulic circuit model containing pumps, valves and actuators based on the hydraulic component library; calling the hydraulic medium model library to establish a temperature-viscosity relationship model to define the physical properties of the working medium; constructing a controller function model based on the state flow diagram; and verifying the control strategy logic of the controller function model through step response and frequency response analysis methods.

4. The method according to claim 3, characterized in that, The construction of the electromechanical-hydraulic coupled dynamic model also includes a high-fidelity model integration step: importing the flexible body description file into the multibody system dynamics environment, replacing the corresponding rigid components, and using node mapping technology to establish the mechanical transmission relationship between the flexible body and adjacent components; and coupling and integrating the parameterized hydraulic circuit model, the controller function model, and the multibody system model containing the flexible body through a defined signal flow interface.

5. The method according to claim 2, characterized in that, The finite element discretization process for the key load-bearing components specifically includes: The geometric model of the key load-bearing component is simplified and repaired. Establish remote points at the assembly interface and set degree-of-freedom constraints and mechanical correlation areas according to the actual connection type; Configure the modal extraction order and damping parameters, and solve to generate a standard modal neutral file containing the mass matrix, stiffness matrix and mode shapes.

6. The method according to claim 2, characterized in that, The process of performing virtual-real closed-loop interaction also includes: The high-fidelity dynamic model is solved using a variable step-size integral algorithm; Based on the flexible body description file integrated in the model, stress recovery technology is used to calculate and output the stress distribution and deformation state of the key load-bearing components in real time.

7. The method according to claim 1, characterized in that, The construction of the digital twin visualization includes: Construct a three-dimensional model of the hydraulic support, conveying equipment, and the roof coal seam and its collision bodies, and establish the parent-child hierarchical relationship between the components; Add a rigid body component to the three-dimensional model and set its mass and friction coefficient parameters; The kinematic logic of the support structure is established based on a finite state machine, and the work cycle action rules, including column lowering, support shifting, column raising, and slide pushing, are defined to control the motion response of the virtual components.

8. The method according to claim 1, characterized in that, The execution of the virtual-real closed-loop interaction specifically includes: The visualization interaction module parses the pose and load data of the physical hydraulic support and uses an interpolation algorithm to drive the digital twin to update its visual state. The initial state parameters extracted from the analysis are encoded with the action instructions and sent to the simulation calculation module via a network protocol; The simulation calculation module performs simulations based on the received instructions and provides real-time feedback on calculation results, including column pressure, displacement, and hydraulic system status, which are presented in a multimodal form in the visualization interaction module.

9. The method according to claim 6, characterized in that, The method further includes: The measured data of the physical hydraulic support are compared and analyzed in real time with the dynamic parameters fed back by the simulation calculation module. The accuracy of the high-fidelity dynamic model is verified according to the error evaluation index.

10. A digital twin system for hydraulic supports, characterized in that, include: The electromechanical-hydraulic coupling modeling unit is used to construct a high-fidelity dynamic model that integrates the flexible characteristics of key load-bearing components, hydraulic dynamic characteristics, and electronic control logic. Virtual twin building blocks are used to construct digital twins of hydraulic supports with physical attributes, collision detection, and motion logic control. The closed-loop interactive control unit is used to connect the physical hydraulic support, the high-fidelity dynamic model, and the digital twin via a bidirectional data link to achieve real-time state mapping drive and simulation data feedback.

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