A kind of automatic spray car and control method for setting point and time in coal mine underground roadway

Abstract

This invention provides a self-setting automatic spraying vehicle and control method for fixed-point and timed operation in underground coal mine roadways, including a monorail traveling mechanism, an explosion-proof on-board frame assembly, a water spraying system, and a mining intrinsically safe electrical control system. This invention supports full-dimensional customization of parameters such as operating point, spraying duration, and cycle period, achieving precise dust suppression on demand and significantly saving clean water resources. Employing an encoder integral closed-loop positioning algorithm, it has small fixed-point stopping errors and can form precise fog curtains in segments, reducing the concentration of suspended coal dust and preventing the risk of coal dust explosions. All mechanical and electrical components of the machine comply with mining explosion-proof and intrinsically safe standards. The system is equipped with multiple safety interlocking mechanisms, including pedestrian avoidance, water shortage protection, fault self-locking, and dust emergency linkage, meeting coal mine safety production regulations, supporting unattended operation, and reducing labor costs. The PLC modular intelligent control system ensures that parameters are not lost after power failure, maintains rigorous logic, guarantees long-term stable operation, and is easy and efficient to maintain.

Description

Technical Field

[0001] This invention relates to the technical field of dust suppression equipment in coal mines, specifically to an automatic sprayer and control method for fixed-point, timed, and self-setting spraying in underground coal mine roadways. Background Technology

[0002] Coal mining operations and auxiliary transportation processes continuously generate large amounts of suspended coal dust. This suspended coal dust can cause occupational diseases such as pneumoconiosis among workers, and high concentrations of coal dust can easily trigger explosions when exposed to electrical sparks underground, seriously threatening safe production in the mine.

[0003] Currently, dust suppression equipment in domestic coal mine roadways generally adopts fixed-point spray devices, which, combined with existing technology, have the following core technical defects: 1. The equipment is fixed and cannot be moved, and can only cover a single local area. It cannot achieve precise dust suppression at multiple points and in segments over long-distance roadways, and the spread of coal dust at the far end of the roadway cannot be effectively controlled. 2. The spraying sequence is rigid and inflexible, making it impossible to customize the work points, spraying duration, and cycle interval according to the working conditions at the well site. This results in frequent ineffective spraying and serious waste of clean water resources at the well site. 3. It lacks high-precision walking and positioning closed-loop control, and has no autonomous inspection or precise fixed-point stopping function, making it unable to meet the distributed dust suppression needs of long-distance underground roadways. 4. Traditional equipment has an incomplete safety protection system, lacking pedestrian avoidance, water shortage protection, fault self-locking, and dust linkage emergency spray mechanism, posing a safety hazard if personnel accidentally enter the work area; 5. Most existing underground mobile spraying equipment is a wheeled locomotive with a floor plate. Water, silt, and debris on the floor of underground roadways can easily cause the equipment to slip and get stuck, resulting in extremely poor adaptability to passage. At the same time, there is no systematic PLC intelligent control algorithm, and it is only a simple switch-type control, with low levels of automation and intelligence.

[0004] In summary, existing technologies cannot meet the requirements for underground dust suppression spraying in coal mines, which features suspended mobile operation, precise fixed-point docking, fully customizable on-site parameters, fully automated unattended operation, explosion-proof safety interlocks, and intelligent algorithm closed-loop control. Therefore, this paper proposes a fixed-point, timed, self-setting automatic spraying vehicle and its control method for use in underground coal mine roadways. Summary of the Invention

[0005] The purpose of this invention is to address the industry pain points of existing fixed spraying devices, such as poor mobility, inability to customize timing parameters, high water resource consumption, lack of safety interlocks, limited underground access for wheeled equipment, and lack of intelligent algorithm support for traditional control. Utilizing the suspension track of a common I-beam monorail in coal mines, this invention enables autonomous movement across multiple points in long-distance roadways, free setting of underground parameters, fully automatic closed-loop spraying at fixed points and times, and unattended cyclic operation around the clock. All hardware components meet the explosion-proof and intrinsically safe standards for mining applications, making it suitable for the extremely harsh environments of underground mines, characterized by flammable and explosive gas, high humidity, and abundant coal dust.

[0006] To achieve the above-mentioned objectives, the present invention provides the following technical solution: a fixed-point, timed, self-setting automatic spraying vehicle for underground coal mine roadways, comprising a monorail traveling mechanism, an explosion-proof vehicle-mounted frame assembly, a water spraying system, and a mine-use intrinsically safe electrical control system; the monorail traveling mechanism includes a track, two sets of traveling wheel sets, and a synchronous connecting rod. Each set of traveling wheel sets includes two drive wheels symmetrically arranged on both sides of the track and two brake wheels. The drive wheels contact and cooperate with the track line to achieve driving movement. The two sets of traveling wheel sets are rigidly connected by a high-strength synchronous connecting rod; the traveling mechanism is equipped with a drive motor and a braking unit. The output shaft of the motor is connected to the drive wheels via a reducer. A controller is mounted on the side of the motor. The braking unit is symmetrically arranged on both sides of the traveling mechanism, including a brake cylinder, a brake arm, a brake shoe shaft, and a brake wheel set. The brake cylinder includes a cylinder barrel, a piston rod, and a brake wheel set. The moving spring has triple protection functions: automatic braking, parking lock, and emergency power-off braking. The vehicle-mounted explosion-proof frame assembly is made of Q355B low-alloy high-strength steel box-type welding. The top of the frame is hinged to the suspension bracket of the monorail crane traveling mechanism through the suspension tongue. The water spray system includes a vertical centrifugal pump, water tank, dust suppressant tank, multi-way pipeline, solenoid valve group, atomizing nozzles, and water spray heads. Four atomizing nozzles are located on the top of the frame for full coverage atomization in the roadway, and two water spray heads are located on both sides of the frame for dust suppression. The intrinsically safe electrical control system for mining includes an intrinsically safe PLC controller, a travel mileage encoder, an infrared human body detection sensor, a mining dust concentration sensor, a water tank level sensor, a medicine tank level sensor, an intrinsically safe explosion-proof battery, and a relay drive circuit. All sensors and actuators are electrically connected to the PLC controller.

[0007] As a preferred technical solution of the present invention, the brake spring of the braking unit is sleeved on the outside of the piston rod of the brake cylinder. When the system malfunctions or an obstacle is detected, the braking unit can quickly lock the walking wheel assembly to realize emergency braking and locking of the whole machine.

[0008] As a preferred technical solution of the present invention, the water spray system can realize automated operation under multiple working conditions, including five working modes: water spraying, automatic water tank dosing, chemical circulation and mixing, high-pressure spray dust suppression, and chemical tank replenishment. Each working mode is automatically switched by opening and closing the corresponding solenoid valve and electric ball valve.

[0009] As a preferred technical solution of the present invention, the intrinsically safe electrical control system for mining is equipped with an explosion-proof human-machine interface touch screen, which can be customized and entered on-site with parameters such as fixed-point mileage coordinates of the roadway, single-point spray duration, walking speed, cycle operation period, dust safety threshold, water shortage warning level and docking error parameters. All parameters are stored in the PLC power-off retention register after being verified by the algorithm, and the parameters are not lost after power failure and restart.

[0010] A control method for a fixed-point, timed, self-setting automatic sprayer for underground coal mine roadways includes the following operational steps: S1. The equipment is connected to the 127V explosion-proof power supply in the well. The PLC controller completes the power-on initialization self-test of the entire system hardware. After the sensor and actuator signals are normal and the water tank level reaches the standard, it enters the standby state. S2. Operators input custom operating parameters through an explosion-proof touch screen. After abnormal parameters are filtered by the parameter boundary limiting algorithm, the parameters are locked and stored. S3 and PLC drive the walking mechanism to operate, and calculate the equipment's walking position in real time through the walking mileage integral positioning algorithm. Based on the fixed point threshold judgment algorithm, the equipment completes the precise stopping of each preset work fixed point. S4. After the equipment is locked at a fixed point, the spraying operation is started. The spraying duration is controlled by a fixed-point timed closed-loop timing algorithm. After the operation at a single point is completed, the equipment will automatically move to the next operation point. S5. After completing the full-area spraying operation at all preset points, the equipment reverses and resets to the initial origin, entering a low-power cycle standby state. After the standby cycle ends, the next cycle of operation will start automatically. S6. The entire operation is monitored in real time through a multi-level signal priority interlocking algorithm. When an emergency signal is triggered, the shutdown and interlocking actions are executed first. After the fault is cleared, the original operation sequence is automatically resumed.

[0011] As a preferred technical solution of the present invention, the PLC controller integrates an adaptive acceleration / deceleration control algorithm between points and a walking distance integral positioning algorithm. The equipment relies on a walking encoder to achieve closed-loop detection of the overall position. It calculates the walking distance of the equipment relative to the initial origin in real time through the principle of pulse integral accumulation, providing a data basis for fixed-point stopping. Algorithm formula: In the formula: S is the cumulative travel mileage of the equipment; D is the outer diameter of the travel drive wheel; i is the total transmission ratio of the reduction mechanism; N represents the total number of pulses output by the encoder per revolution; N represents the number of pulses accumulated and acquired by the PLC in real time. The system periodically refreshes mileage data to complete real-time calculation of the entire track position of the machine.

[0012] As a preferred technical solution of the present invention, the fixed-point threshold judgment and precise docking algorithm All tunnel operation coordinates are pre-entered into the PLC register. Set the allowable docking error threshold S for the equipment. Real-time algorithm decision logic: In the formula: The device's position is calculated in real time; The location is the preset position for the nth task. When the inequality is true, the PLC immediately outputs a stop signal, the travel motor brakes, the equipment stops precisely and the spraying program starts; if the condition is not met, the equipment continues to travel along the track, achieving fixed-point operation without overshoot or deviation.

[0013] As a preferred technical solution of the present invention, an adaptive acceleration / deceleration control algorithm between points is provided. To address the issues of frame vibration, braking shock, and fixed-point overshoot caused by rigid start-stop, a segmented speed adaptive algorithm is designed: Away from fixed point range: The equipment operates at a rated constant speed Stable walking; Entering the fixed-point warning distance range: PLC automatically adjusts speed to low speed. Slow down; Upon entering the fixed threshold range: directly and smoothly stop the machine and apply the brake; It effectively improves the smoothness of monorail crane operation, reduces the risk of derailment, and is suitable for long-distance continuous travel in underground mines.

[0014] As a preferred technical solution of the present invention, a self-defined parameter storage and boundary limiting algorithm is provided. To address the self-defined core function in the title of this invention, a parameter non-volatile storage and secure limiting algorithm is designed: Operators can input all parameters via the touchscreen, including the number of fixed points, point coordinates, spray duration, cycle interval, and walking speed. The PLC has built-in upper and lower limit constraint algorithms. Extremely abnormal parameters mistakenly entered by personnel are filtered out to prevent disorderly operation of equipment; all valid parameters are stored in the PLC power-off retention register, and the parameters are fully retained after the mine is powered off or the equipment is restarted, without the need for secondary reset.

[0015] As a preferred technical solution of the present invention, a fixed-point timing closed-loop timing algorithm is provided. After the equipment is locked at its designated stop point, the incremental timer inside the PLC starts counting and accumulating the duration of this spraying operation in real time. Closed-loop decision logic: When the real-time cumulative spraying time reaches the user-preset time. At this time, the PLC automatically shuts off the high-pressure water pump and the water distribution solenoid valve, and the current fixed-point spraying operation ends, and the equipment enters the next node's travel process; Multi-point sequential queue cyclic scheduling algorithm Construct an ordered queue model for roadway work points: The system traverses all work points sequentially according to the queue number, and executes the single work process of walking, stopping, timed spraying, and shutting down the waterway in a loop. After the work is completed at all points in the entire tunnel, the equipment automatically reverses and resets to the initial origin, starts the cycle and waits for the timer. After the timer reaches the target, it automatically starts the next round of full-area cycle operation, realizing unattended reciprocating operation around the clock. Dust Concentration Adaptive Intelligent Spray Algorithm By combining real-time data collected by downhole dust sensors, the spray duration can be dynamically adjusted adaptively, breaking away from the fixed-duration spray pattern and balancing dust suppression effectiveness with downhole water conservation needs. In the formula: C is the real-time dust concentration in the roadway; The system sets a safety dust concentration threshold for mines; the more severe the dust pollution in the roadway, the longer the automatic spraying time of the system; once the dust concentration reaches the standard, normal operations are resumed, significantly reducing ineffective water consumption. Multi-level signal priority interlocking algorithm Adhering to the principle of safety first in underground coal mines, the PLC has a built-in fixed priority scheduling algorithm that strictly sorts the execution priority of signals throughout the entire cycle from high to low: Pedestrian infrared emergency stop signal > Water tank low water protection signal > Equipment malfunction self-locking signal > Dust exceeding limit emergency spray signal > Regular fixed-point timed operation procedure When any high-level danger signal is triggered, all current running programs will be interrupted directly, and the entire machine will be shut down and locked first. Low-level routine operation programs will be temporarily suspended, and the system will automatically resume the original operation sequence after the dangerous condition is completely eliminated.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Strong adaptability to underground passage: It travels on a suspended track using a general-purpose monorail crane in coal mines, completely avoiding the problems of silt, water accumulation, and debris blockage on the roadway floor, and is suitable for all working conditions of all main roadways, return airways, and auxiliary transport roadways underground.

[0017] 2. Full-dimensional parameter customization: The working point, spray duration, and cycle can be freely set on the downhole site to achieve precise dust suppression as needed, eliminate ineffective spraying from the source, and significantly save precious clean water resources downhole.

[0018] 3. High positioning accuracy: With the support of encoder integral closed-loop positioning algorithm, the fixed-point stopping error is small, and the segmented fog curtain dust suppression in the roadway significantly reduces the concentration of airborne coal dust and avoids major safety hazards of coal dust explosion.

[0019] 4. Fully explosion-proof underground adaptability: All mechanical and electrical components of the machine meet the mining explosion-proof and intrinsically safe explosion-proof standards, making it suitable for the extremely harsh environment of underground mines where gas is flammable and explosive, humidity is high, and there is a lot of coal dust.

[0020] 5. Comprehensive safety interlocking system: It integrates multiple safety mechanisms such as pedestrian avoidance, water shortage protection, fault self-locking, and dust emergency linkage, which fully comply with the safety production regulations for underground coal mines. No manual on-site duty is required, which greatly reduces the labor cost of underground operations.

[0021] 6. Stable closed-loop intelligent algorithm: The PLC modular intelligent control system is complete, parameters are permanently saved after power failure, the timing logic is rigorous, the long-term continuous operation stability in the well is strong, and daily maintenance is simple. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the spray truck of the present invention; Figure 2 This is a right view of the spray truck of the present invention; Figure 3 This is a structural diagram of the water spray section of the present invention; Figure 4 This is the control flowchart of the present invention; Figure 5 This is the algorithm control diagram of the present invention; Figure 6 This is the control loop diagram of the present invention.

[0023] In the diagram: 1. Track; 2. Drive wheel; 3. Brake wheel; 4. Pin; 5. Connecting rod; 6. Solenoid valve a; 7. Solenoid valve b; 8. Water inlet; 9. Water tank level sensor; 10. Reducer; 11. Motor; 12. Control box; 13. Frame; 14. Battery; 15. Control box; 16. Oil pump motor; 17. Controller; 18. Vertical centrifugal pump; 19. Water tank; 20. Medicine tank level sensor; 21. 21. Medicine tank; 22. Piston rod; 23. Brake spring; 24. Piston connecting rod; 25. Brake shoe shaft; 26. Brake arm; 27. Cylinder; 28. Cylinder bottom; 29. ​​Spray bar; 30. Atomizing nozzle; 31. Sprinkler head; 32. Spray pump; 33. Solenoid valve c; 34. Solenoid valve d; 35. Electric ball valve a; 36. Water outlet; 37. Lifting tongue; 38. Solenoid valve e; 39. Electric ball valve b; 40. Dosing port. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0025] Therefore, the following detailed description of the embodiments of the present invention is not intended to limit the scope of the claimed invention, but merely illustrates some embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention. It should be noted that, in the absence of conflict, the embodiments and features and technical solutions in the embodiments of the present invention can be combined with each other. It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0026] Example 1: An automatic spraying vehicle for fixed-point and timed operation in underground coal mine roadways, with a suspended walking mechanism: Each drive unit includes two drive wheels 2 and two brake wheels 3, symmetrically arranged on both sides of the track 1. The drive wheels 2 roll on the track 1 in line contact and are responsible for driving. The two sets of walking wheels are connected by a high-strength synchronous connecting rod to ensure that the speed of the two wheel sets is consistent during walking, avoiding derailment due to uneven load and improving the stability of operation.

[0027] The output shaft of motor 11 is connected to the drive wheel 2 of the travel wheel set via reducer 10, and controller 12 is connected to the side of motor 11. The braking unit consists of a brake cylinder, brake arm 26, brake shoe shaft 25, and brake wheel set 3. There is a braking unit on each side. The brake cylinder consists of a piston rod 22 inserted into a cylinder barrel 27, and a brake spring 23 is fitted on the outside. It has triple protection functions of automatic driving braking, parking locking, and emergency power failure braking. When the system malfunctions or detects an obstacle, it can quickly lock the wheel set to ensure safety.

[0028] Vehicle-mounted explosion-proof frame assembly: The load-bearing vehicle body 14 is the core carrier of the device. The entire frame is made of Q355B low-alloy high-strength steel through a box-type welding process, resulting in high structural strength and light weight. The top of the frame is connected to the suspension bracket pins 4 of the monorail traveling mechanism via two suspension tongues 32.

[0029] Water spray system: A vertical centrifugal pump 18 is used as the high-pressure water pump. The main liquid supply pipeline uses high-pressure stainless steel pipe, and the branch pipelines extend along the left, right and front and rear of the vehicle frame. Four atomizing nozzles 30 are installed to cover the tunnel; two water spray heads 31 are installed on both sides of the vehicle frame to suppress dust. Through the multi-directional nozzle layout, atomized coverage of the entire cross-section of the tunnel without dead angles is achieved.

[0030] Work process (such as) Figure 6 (1) Sprinkling stage: The vertical centrifugal pump 18 pumps water from the water tank 19 through the outlet 36 and the solenoid valve a6 to the sprinkler head 31 to spray the water.

[0031] Water tank dosing stage: The dust suppressant in the dust suppressant tank 21 flows into the water tank through the solenoid valves 33c and 34d and the outlet 36.

[0032] Uniform mixing stage of medicine and water: Vertical centrifugal pump 18 draws the medicine and water mixture in water tank 19 out of water outlet 36 and flows into water tank through solenoid valve b7, so that the medicine and water are uniformly mixed.

[0033] Spraying stage: The oil pump motor 16 drives the spray pump 32 to draw the drug mixture out from the outlet 36 and flow through the electric ball valve d34 to the top of the water tank, and then spray the drug through the spray bar 29 and nozzle 30.

[0034] During the replenishment stage: the spray pump 32 draws in the medicine from the dosing port 40, pressurizes it through the solenoid valve e39, flows through the electric ball valve b, and finally reaches the medicine tank 21.

[0035] Intrinsically Safe Electrical Control System for Mining: The intrinsically safe PLC controller is the brain and control core of the entire equipment, and is an intrinsically safe, explosion-proof type for mining. A travel mileage encoder is installed on the traveling mechanism to monitor the equipment's travel distance, speed, and position in real time. An intrinsically safe infrared human body detection sensor detects whether personnel are approaching from the front or side of the equipment. A mining dust concentration sensor collects real-time dust concentration data in the underground roadway and uploads it to the PLC. Water tank level sensor 9 and medicine tank level sensor 20 are installed inside water tank 19 and medicine tank 21, respectively, to monitor the water level in real time. An intrinsically safe explosion-proof battery 14 provides a stable, safe, and explosion-proof DC power supply for the intrinsically safe PLC, all sensors, and signal circuits. The relay actuation drive circuit is used because the PLC control signal power is too low to directly drive the water pump, solenoid valve, and spray actuator.

[0036] Example 2: This example is applied to an auxiliary haulage roadway in a coal mine. The roadway is 800m long, with 6 pre-set dust suppression operation locations. The equipment is equipped with a mine-use explosion-proof and intrinsically safe KXH series PLC controller, a matching explosion-proof human-machine interface touch screen, and a walking mechanism adapted to the existing I-beam monorail track in the mine. (e.g.) Figure 4 ) 1. On-site parameter preset Operators can input custom operating parameters on-site via an explosion-proof touchscreen: 6 fixed-point roadway mileage coordinates, single-point basic spray duration of 60s, rated walking speed between points of 0.5m / s, overall machine cycle operation period of 2h, and dust safety threshold. Water tank low water warning level, docking tolerance All parameters are automatically stored in the PLC power-off retention register after being verified by the limiting algorithm.

[0037] 2. Power-on initialization self-test The equipment is connected to the 127V explosion-proof power supply in the well. The PLC completes the hardware self-test of the entire system, including the controller, sensors, walking motor, and water circuit solenoid valve. The sensor signals are normal, the water tank level is sufficient, and the equipment enters the standby ready state.

[0038] 3. First round of full-area cyclical operation The PLC drives the walking motor to start, and the whole machine moves forward along the track. The encoder provides real-time feedback of walking pulses, and the mileage integration algorithm calculates the equipment position in real time. After reaching the first fixed point, the threshold judgment algorithm is triggered, the motor stops and the brake is engaged, and the spray system starts spraying continuously for 60 seconds. After the timing algorithm reaches the target, the water circuit is automatically shut off. Then the equipment moves to the second to sixth fixed points in sequence, repeating the complete process of fixed point stopping and timed spraying.

[0039] 4. Job reset and weekly standby After all six fixed-point full-area spraying operations are completed, the entire machine reverses and resets to its initial origin. The PLC starts the cycle timer and enters a 2-hour low-power standby state. After the standby timer ends, the system automatically starts the next cycle operation.

[0040] 5. Actual measurements of emergency operating conditions for each interlock Pedestrian avoidance emergency: If a worker enters the equipment's operating area in the alley, the infrared sensor triggers a signal. The safety priority algorithm determines it to be the highest level signal, and the PLC immediately cuts off all walking and spraying outputs, and the entire machine is locked in an emergency. After the personnel evacuate the safe area, the system automatically resumes the original operating sequence.

[0041] Dust exceeding limit emergency: If the real-time dust concentration in the roadway is higher than the safety threshold, the system skips the standby timer and forcibly starts the spraying operation; after the dust concentration drops below the safety value, it resumes normal preset program operation.

[0042] Emergency water shortage protection: When the water tank level is lower than the warning threshold, the level sensor triggers a protection signal, and the entire machine automatically locks down; after manual water replenishment to the safe level, the equipment automatically unlocks and resumes operation.

[0043] Emergency Response to Equipment Failures: Upon triggering fault signals such as overload of the travel motor or pipeline leakage, the system will immediately stop, self-lock, and sound an alarm. Operation can only be restarted after the fault has been resolved. Example 3: A control method for a self-setting automatic sprayer truck with fixed location and time in underground coal mine roadways, based on the complete core intelligent control algorithm of this invention. This invention integrates eight modular intelligent control algorithms within the PLC, fully covering all control aspects including positioning, movement, parameter control, timing, sequence control, adaptive control, and safety. All algorithms are embedded in the PLC program and run in a closed loop. The specific algorithm principles, mathematical models, and decision logic are as follows: (1) Walking distance integral positioning algorithm The equipment relies on a walking encoder to achieve closed-loop detection of the overall position. It calculates the walking distance of the equipment relative to the initial origin in real time through the principle of pulse integral accumulation, providing a data basis for fixed-point stopping.

[0044] Algorithm formula: In the formula: S is the cumulative travel mileage of the equipment; D is the outer diameter of the travel drive wheel; i is the total transmission ratio of the reduction mechanism; N represents the total number of pulses output per revolution by the encoder; N represents the number of pulses accumulated and acquired by the PLC in real time.

[0045] The system periodically refreshes mileage data to complete real-time calculation of the entire track position of the machine.

[0046] (2) Fixed-point threshold judgment and precise docking algorithm All tunnel operation coordinates are pre-entered into the PLC register. Set the allowable docking error threshold S for the equipment. Real-time algorithm decision logic: In the formula: The device's position is calculated in real time; This is the location of the nth preset task.

[0047] When the inequality is true, the PLC immediately outputs a stop signal, the travel motor brakes, the equipment stops precisely and the spraying program starts; if the condition is not met, the equipment continues to travel along the track, achieving fixed-point operation without overshoot or deviation.

[0048] (3) Inter-point adaptive acceleration and deceleration control algorithm To address the issues of frame vibration, braking shock, and fixed-point overshoot caused by rigid start-stop, a segmented speed adaptive algorithm is designed: Away from fixed point range: The equipment operates at a rated constant speed Stable walking; Entering the fixed-point warning distance range: PLC automatically adjusts speed to low speed. Slow down; Entering the fixed threshold range: directly and smoothly stop the machine and apply the brake.

[0049] It effectively improves the smoothness of monorail crane operation, reduces the risk of derailment, and is suitable for long-distance continuous travel in underground mines.

[0050] (4) Self-defined parameter storage and boundary limiting algorithm To address the self-defined core function in the title of this invention, a parameter non-volatile storage and secure limiting algorithm is designed: Operators can input all parameters via the touchscreen, including the number of fixed points, point coordinates, spray duration, cycle interval, and walking speed. The PLC has built-in upper and lower limit constraint algorithms. Extremely abnormal parameters mistakenly entered by personnel are filtered out to prevent disorderly operation of equipment; all valid parameters are stored in the PLC power-off retention register, and the parameters are fully retained after the mine is powered off or the equipment is restarted, without the need for secondary reset.

[0051] (5) Fixed-point timing closed-loop timing algorithm After the equipment is locked at its designated stop point, the incremental timer inside the PLC starts counting and accumulating the duration of this spraying operation in real time. Closed-loop decision logic: When the real-time cumulative spraying time reaches the user-preset time. At this time, the PLC automatically shuts off the high-pressure water pump and the water distribution solenoid valve, ending the current fixed-point spraying operation, and the equipment enters the next node's travel process.

[0052] (6) Multi-point sequential queue cyclic scheduling algorithm Construct an ordered queue model for roadway work points: The system sequentially traverses all work points according to the queue number, and cyclically executes single work processes such as walking, stopping, timed spraying, and shutting down waterways. After all work is completed at all points in the entire tunnel, the equipment automatically reverses and resets to the initial origin, starts the cycle and waits for the timer. Once the timer reaches the target, it automatically starts the next round of full-area cyclical work, achieving unattended reciprocating operation around the clock.

[0053] (7) Dust Concentration Adaptive Intelligent Spraying Algorithm By combining real-time data collected by downhole dust sensors, the spray duration can be dynamically adjusted adaptively, breaking away from the fixed-duration spray pattern and balancing dust suppression effectiveness with downhole water conservation needs. In the formula: C is the real-time dust concentration in the roadway; This sets the safety dust concentration threshold for the mine. The more severe the dust pollution in the roadway, the longer the automatic spraying time of the system; once the dust concentration reaches the standard, normal operations can resume, significantly reducing ineffective water consumption.

[0054] (8) Multi-level signal priority interlocking algorithm Adhering to the principle of safety first in underground coal mines, the PLC has a built-in fixed priority scheduling algorithm that strictly sorts the execution priority of signals throughout the entire cycle from high to low: Pedestrian infrared emergency stop signal > Water tank low water protection signal > Equipment malfunction self-locking signal > Dust exceeding limit emergency spray signal > Regular fixed-point timed operation procedure When any high-level danger signal is triggered, all current running programs will be interrupted directly, and the entire machine will be shut down and locked first. Low-level routine operation programs will be temporarily suspended, and the system will automatically resume the original operation sequence after the dangerous condition is completely eliminated.

[0055] 4. Complete PLC Control Method and Flowchart Combining all the above algorithms, the overall PLC control flow of this invention is divided into 7 closed-loop steps (such as...). Figure 5 ): Power-on initialization self-test: When the equipment is connected to the underground explosion-proof power supply, the PLC completes a full hardware circuit self-test. If there is no fault, it enters standby mode; if there is a fault, it will self-lock and alarm.

[0056] Parameter reading and verification: Retrieve custom job parameters from the storage area, and verify and lock valid parameters using a limiting algorithm.

[0057] Walking distance calculation: Drive the walking mechanism to run and rely on the integral positioning algorithm to calculate the equipment position in real time.

[0058] Fixed-point stopping and braking: After reaching the target point through a threshold determination algorithm, the engine stops and the brake locks the vehicle body.

[0059] Timed spraying operation: The water system is activated, and the timing algorithm accumulates the time. The spraying will automatically stop after the target is reached.

[0060] Global point traversal and reset: After completing all point operations in sequence, the equipment resets to the origin and enters a cycle-based standby mode.

[0061] Full-process safety interlock control: Real-time monitoring of interlocking algorithms throughout the entire operation cycle, priority response to emergency signals, and automatic resumption of operation after fault clearance.

[0062] The above embodiments are only used to illustrate the present invention and are not intended to limit the technical solutions described herein. Although the present invention has been described in detail with reference to the above embodiments, the present invention is not limited to the specific embodiments described above. Therefore, any modifications or equivalent substitutions to the present invention, as well as all technical solutions and improvements that do not depart from the spirit and scope of the invention, are covered within the scope of the claims of the present invention.

Claims

1. A self-setting automatic spraying vehicle for fixed-point and timed operation in underground coal mine roadways, characterized in that, The system includes a monorail traveling mechanism, an explosion-proof vehicle frame assembly, a water spray system, and an intrinsically safe electrical control system for mining. The monorail traveling mechanism includes a track (1), two sets of traveling wheels and a synchronous connecting rod. Each set of traveling wheels includes two driving wheels (2) symmetrically arranged on both sides of the track (1) and two brake wheels (3). The driving wheels (2) are in line contact with the track (1) to achieve driving. The two sets of traveling wheels are rigidly connected by a high-strength synchronous connecting rod. The traveling mechanism is equipped with a drive motor (11) and a braking unit. The output shaft of the motor (11) is connected to the driving wheel (2) through a reducer (10). A controller (17) is mounted on the side of the motor (11). The braking unit is symmetrically arranged on both sides of the traveling mechanism and includes a brake cylinder, a brake arm (26), a brake shoe shaft (25), and a brake wheel set. The brake cylinder includes a cylinder barrel (27), a piston rod (22), and a brake spring (23). It has automatic braking and parking functions. The vehicle-mounted explosion-proof frame assembly is made of Q355B low-alloy high-strength steel box-type welding. The top of the frame is hinged to the suspension bracket of the monorail crane traveling mechanism through the suspension tongue (37). The water spray system includes a vertical centrifugal pump (18), a water tank (19), a dust suppressant tank (21), multiple pipelines, a solenoid valve group, atomizing nozzles (30) and water spray heads (31). Four atomizing nozzles (30) are set on the top of the frame for full coverage atomization in the roadway, and two water spray heads (31) are set on both sides of the frame for dust suppression. The intrinsically safe electrical control system for mining includes an intrinsically safe PLC controller, a travel mileage encoder, an infrared human body detection sensor, a mining dust concentration sensor, a water tank level sensor (9), a medicine tank level sensor (20), an intrinsically safe explosion-proof battery (14), and a relay execution drive circuit. All sensors and actuators are electrically connected to the PLC controller.

2. The automatic spraying vehicle for fixed-point and timed operation in underground coal mine roadways according to claim 1, characterized in that, The brake spring (23) of the brake unit is sleeved on the outside of the brake cylinder piston rod (22). When the system malfunctions or an obstacle is detected, the brake unit can quickly lock the walking wheel set.

3. The automatic spraying vehicle for fixed-point and timed operation in underground coal mine roadways according to claim 1, characterized in that, The water spray system can realize automated operation under multiple working conditions, including five working modes: water spraying, automatic dosing of water tank (19), chemical circulation and mixing, high-pressure spray dust suppression and chemical tank (21) replenishment. Each working mode can be switched automatically by opening and closing the corresponding solenoid valve and electric ball valve.

4. The automatic spraying vehicle for fixed-point and timed operation in underground coal mine roadways according to claim 1, characterized in that, The intrinsically safe electrical control system for mining is equipped with an explosion-proof human-machine interface touch screen, which allows for on-site input of roadway fixed-point mileage coordinates, single-point spray duration, walking speed, cycle operation period, dust safety threshold, water shortage warning level, and docking error parameters. All parameters are stored in the PLC power-off retention register after being verified by the algorithm, and the parameters are not lost after power failure and restart.

5. A control method for a self-setting automatic spraying vehicle for fixed-point and timed operation in underground coal mine roadways, applied to the automatic spraying vehicle described in any one of claims 1-4, characterized in that, The following work steps are included: S1. The equipment is connected to the 127V explosion-proof power supply in the well. The PLC controller completes the power-on initialization self-test of the entire system hardware. After the sensor and actuator signals are normal and the water tank level reaches the standard, it enters the standby state. S2. Operators input custom operating parameters through an explosion-proof touch screen. After abnormal parameters are filtered by the parameter boundary limiting algorithm, the parameters are locked and stored. S3 and PLC drive the walking mechanism to operate, and calculate the equipment's walking position in real time through the walking mileage integral positioning algorithm. Based on the fixed point threshold judgment algorithm, the equipment completes the precise stopping of each preset work fixed point. S4. After the equipment is locked at a fixed point, the spraying operation is started. The spraying duration is controlled by a fixed-point timed closed-loop timing algorithm. After the operation at a single point is completed, the equipment will automatically move to the next operation point. S5. After completing the full-area spraying operation at all preset points, the equipment reverses and resets to the initial origin, entering a low-power cycle standby state. After the standby cycle ends, the next cycle of operation will start automatically. S6. The entire operation is monitored in real time through a multi-level signal priority interlocking algorithm. When an emergency signal is triggered, the shutdown and interlocking actions are executed first. After the fault is cleared, the original operation sequence is automatically resumed.

6. The control method for a self-setting automatic spraying vehicle with fixed location and time according to claim 5, characterized in that, The PLC controller integrates an adaptive acceleration / deceleration control algorithm between points and a mileage integral positioning algorithm. The equipment relies on a walking encoder to achieve closed-loop detection of the overall position. It calculates the walking distance of the equipment relative to the initial origin in real time through the principle of pulse integral accumulation, providing a data basis for fixed-point stopping. Algorithm formula: In the formula: S is the cumulative travel mileage of the equipment; D is the outer diameter of the travel drive wheel; i is the total transmission ratio of the reduction mechanism; This represents the total number of output pulses per revolution of the encoder. N represents the number of pulses collected in real time by the PLC; The system periodically refreshes mileage data to complete real-time calculation of the entire track position of the machine.

7. The control method for a self-setting automatic spraying vehicle with fixed location and time according to claim 5, characterized in that, Fixed-point threshold judgment and precise docking algorithm: All fixed-point coordinates of roadway operations are pre-entered into the PLC register. Set the allowable docking error threshold S for the equipment. Real-time algorithm decision logic: In the formula: The device's position is calculated in real time; The location is the preset position for the nth task. When the inequality is true, the PLC immediately outputs a stop signal, the travel motor brakes, the equipment stops precisely and the spraying program starts; if the condition is not met, the equipment continues to travel along the track, achieving fixed-point operation without overshoot or deviation.

8. The control method for a self-setting automatic spraying vehicle with fixed location and time according to claim 5, characterized in that, Inter-point adaptive acceleration / deceleration control algorithm: To address the frame vibration, braking impact, and fixed-point overshoot issues caused by rigid start-stop, a segmented speed adaptive algorithm is designed. Away from fixed point range: The equipment operates at a rated constant speed Stable walking; Entering the fixed-point warning distance range: PLC automatically adjusts speed to low speed. Slow down; Entering the fixed threshold range: directly and smoothly stop the machine and apply the brake.

9. The control method for a self-setting automatic spraying vehicle with fixed location and time according to claim 5, characterized in that, Self-defined parameter storage and boundary limiting algorithm: For the self-defined core function in this invention, a non-volatile parameter storage and safe limiting algorithm is designed. Operators can input all parameters via the touchscreen, including the number of fixed points, point coordinates, spray duration, cycle interval, and walking speed. The PLC has built-in upper and lower limit constraint algorithms. Extremely abnormal parameters mistakenly entered by personnel are filtered to prevent disorderly operation of equipment; all valid parameters are stored in the PLC power-off retention register, and the parameters are fully retained after the mine is powered off or the equipment is restarted.

10. The control method for a self-setting automatic spraying vehicle with fixed location and time according to claim 5, characterized in that, Fixed-point, timed, closed-loop timing algorithm: After the equipment is locked at a fixed point, the incremental timer inside the PLC starts timing and accumulates the spraying duration in real time. Closed-loop decision logic: When the real-time cumulative spraying time reaches the user-preset time. At this time, the PLC automatically shuts off the high-pressure water pump and the water distribution solenoid valve, and the current fixed-point spraying operation ends, and the equipment enters the next node's travel process; Multi-point sequential queue cyclic scheduling algorithm: Constructing an ordered queue model for roadway work points: The system traverses all work points sequentially according to the queue number, and executes the single work process of walking, stopping, timed spraying, and shutting down the waterway in a loop. After all work is completed at all points in the entire tunnel, the equipment automatically reverses and resets to the initial origin, starts the cycle and waits for the timer. Once the timer reaches the target, it automatically starts the next round of full-area loop operation, running unattended around the clock. Adaptive intelligent spraying algorithm for dust concentration: Combining real-time data collected by downhole dust sensors, it enables adaptive dynamic adjustment of spraying duration, breaking away from the fixed-duration spraying mode and balancing dust suppression effectiveness with downhole water conservation needs. In the formula: C is the real-time dust concentration in the roadway; The threshold for safe dust concentration in the mine is set; the more severe the dust pollution in the roadway, the longer the automatic spraying time of the system; normal operations resume after the dust concentration reaches the standard. Multi-level signal priority interlocking algorithm Adhering to the principle of safety first in underground coal mines, the PLC has a built-in fixed priority scheduling algorithm that strictly sorts the execution priority of signals throughout the entire cycle from high to low: Pedestrian infrared emergency stop signal > Water tank water shortage protection signal > Equipment failure self-locking signal > Dust exceeding limit emergency spray signal > Regular fixed-point timed operation procedure; When any high-level danger signal is triggered, all current running programs will be interrupted directly, and the entire machine will be shut down and locked first. Low-level routine operation programs will be temporarily suspended, and the system will automatically resume the original operation sequence after the dangerous condition is completely eliminated.

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