Intelligent gas drainage system

Abstract

The application provides a kind of intelligent gas drainage system, it is related to gas drainage technical field, the intelligent gas drainage system of the application includes reconfigurable drainage network, distributed sensing network and central intelligent collaborative controller, reconfigurable drainage network includes multiple gas drainage pumps, multiple drainage area pipe networks and the intelligent valve matrix connecting multiple gas drainage pumps and multiple drainage area pipe networks;Distributed sensing network is used to collect the gas concentration and vacuum degree of each drainage area in real time, and the load rate and operating state parameters of each gas drainage pump;Central intelligent collaborative controller is electrically connected with distributed sensing network, intelligent valve matrix and the frequency converter of each gas drainage pump respectively.The intelligent gas drainage system of the application can realize the on-demand dynamic reconfiguration and disturbance-free switching of drainage resources, can effectively improve system energy efficiency and equipment life while ensuring the safety of mining area gas.

Description

Technical Field

[0001] This invention relates to the field of gas extraction technology, and more specifically to an intelligent gas extraction system. Background Technology

[0002] Currently, coal mine gas drainage systems typically consist of multiple gas drainage pumps and multiple drainage pipelines connected to the pre-drainage area and mining area of ​​the coal seam. In actual operation, the gas concentration and vacuum level in each drainage area change dynamically. Existing control methods mostly involve frequency conversion adjustment for individual pumps or manual operation of valves to achieve fixed connections and switching between pumps and pipelines. The drainage resources in each area are relatively independent, lacking system-level coordinated scheduling capabilities.

[0003] However, the existing technologies described above have the following problems: when the gas concentration in a mining area rises sharply, it is impossible to automatically and quickly allocate pumps from other low-demand areas to the emergency area, resulting in insufficient local pumping capacity and potential safety hazards; at the same time, when switching the connection between pumps and areas, there is a lack of smooth load transfer control, which can easily cause drastic fluctuations in pipeline vacuum, affecting pumping stability and even damaging equipment. In addition, under non-emergency conditions, the existing systems also struggle to balance the overall energy efficiency of the pump group and the lifespan of the equipment, resulting in energy waste and uneven equipment wear. Summary of the Invention

[0004] To address the problems in related technologies, this invention provides an intelligent gas extraction system.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] This invention provides an intelligent gas extraction system, comprising:

[0007] A reconfigurable gas drainage network includes multiple gas drainage pumps, multiple drainage area pipelines, and an intelligent valve matrix connecting the multiple gas drainage pumps and the multiple drainage area pipelines.

[0008] A distributed sensor network is used to collect the gas concentration and vacuum level of each extraction area in real time, as well as the load rate and operating status parameters of each gas extraction pump.

[0009] The central intelligent collaborative controller is electrically connected to the distributed sensor network, the intelligent valve matrix, and the frequency converters of each gas extraction pump.

[0010] The central intelligent collaborative controller is configured to execute:

[0011] Based on the relative relationship between the current gas concentration and the safety threshold in each drainage area, and the trend of gas concentration change, the drainage needs of each drainage area are divided into emergency level, normal level, or low level.

[0012] Based on the demand level of each region, the current load rate of each pump, and the operating status parameters, a dynamic pump-region connection topology reconfiguration scheme is determined. Among them, when there is an emergency level region, pumps connected to the lower level region are preferentially switched to the emergency level region.

[0013] According to the topology reconstruction scheme, the pump-area connection relationship is dynamically switched by controlling the intelligent valve matrix;

[0014] During the dynamic switching process, the frequency converter controls the load transfer of the gas extraction pumps involved in the switching, including: gradually changing the speed of the inlet pump and the outlet pump at a smooth rate so that the vacuum fluctuation in the affected area is kept within a preset allowable range.

[0015] Optionally, the specific rules for the central intelligent collaborative controller to classify the extraction and release demand levels are as follows:

[0016] When the gas concentration in a region has reached or exceeded the safety threshold, it is classified as an emergency level.

[0017] When the gas concentration in a region has not reached the safety threshold, but its concentration shows a continuous upward trend relative to the previous moment and the gap between the current concentration and the safety threshold is narrowing, or the current concentration is close to the safety threshold, it is classified as an emergency level.

[0018] When the gas concentration in a region is far below the safety threshold and there is no upward trend in the concentration, or when the concentration is decreasing, it is classified as a low level.

[0019] Other situations are classified as normal.

[0020] Optionally, when the central intelligent collaborative controller makes a decision on the dynamic topology reconfiguration scheme, it also executes energy efficiency optimization rules:

[0021] When there are no emergency zones, reconfigure the pump-zone connection relationship so that the load rate of the gas drainage pumps in operation is as close as possible to their respective preset high-efficiency load range. This includes merging multiple low-load zones to the same pump to increase its load rate to the high-efficiency range and disabling redundant pumps.

[0022] Optionally, when the central intelligent collaborative controller makes a decision on the dynamic topology reconfiguration scheme, it also executes the equipment rotation rule:

[0023] Record the cumulative runtime of each gas drainage pump. When the difference in cumulative runtime of each pump exceeds a preset threshold, switch the pump with the longest runtime to standby during non-emergency periods and connect the healthy pump with the shortest runtime.

[0024] Optionally, when the central intelligent collaborative controller performs load transfer control, the speed increase rate of the input pump and the speed decrease rate of the output pump are both controlled by ramp signals, and the frequency rise time of the input pump and the frequency fall time of the output pump are dynamically adjusted in real time according to the vacuum level feedback of the pumping and discharging area affected by the switching, so that the vacuum level fluctuation of the area does not exceed the preset allowable range.

[0025] Optionally, the intelligent valve matrix includes multiple electrically controlled valves, which are respectively installed at the air inlet of each gas extraction pump, the air outlet of each gas extraction pump, and the interconnecting pipelines between the pipeline networks of each extraction area. Each electrically controlled valve is independently controlled by the central intelligent collaborative controller.

[0026] Optionally, the distributed sensor network includes:

[0027] Gas concentration sensors and vacuum sensors are installed at the pipe inlet of each extraction area;

[0028] Gas concentration sensor, vacuum sensor, flow sensor, temperature sensor and vibration sensor are installed at the inlet and outlet of each gas extraction pump.

[0029] Optionally, the central intelligent collaborative controller is further configured to: after performing topology reconstruction and load transfer, evaluate the effect of changes in gas concentration in each area based on data collected by the sensor network, and record the total system energy consumption before and after this switchover, for use in the demand level classification rules in subsequent dynamic adjustments.

[0030] Optionally, the central intelligent collaborative controller is further configured to: when the health status of a gas drainage pump is determined to be lower than a preset standard based on data collected by a temperature sensor or vibration sensor, mark the pump as a pump to be maintained, and prioritize its removal from the operating network during the next topology reconfiguration, while connecting a backup pump to replace its function.

[0031] Optionally, the smooth rate is achieved by the following method: the inverter output frequency changes according to a fixed linear slope, and when the vacuum degree change rate in the affected area is detected to exceed the preset allowable change rate, the linear slope is automatically reduced until the vacuum degree change rate returns to the allowable range.

[0032] Beneficial effects:

[0033] 1. First, the system of this invention enables rapid and automatic reinforcement of pumping resources to emergency areas, effectively improving system safety. Specifically, in this invention, the central controller assesses the gas concentration and its changing trends in each area in real time, automatically classifying the demand into emergency, normal, and low levels. When an emergency level exists, the pumping pumps in low-level areas are dynamically switched to the emergency area. Compared to existing fixed connections and manual switching methods, this invention can automatically identify high-risk areas and immediately allocate idle pump resources, reducing the response time from minutes to seconds, effectively preventing gas over-limit accidents.

[0034] Secondly, the system of this invention can achieve a smooth transition of vacuum level during pump-zone switching, avoiding damage from pressure shocks. Specifically, during dynamic switching, the speed of the input and output pumps is gradually changed at a smooth rate by a frequency converter, and real-time feedback adjustment is made to keep the vacuum level fluctuations in the affected area within a preset allowable range. In this way, pressure shocks caused by traditional direct valve switching or sudden speed changes can be eliminated, protecting borehole seals, pipelines, and pump equipment, and ensuring the stability and safety of the switching operation.

[0035] Third, the system of this invention enables dynamic, on-demand scheduling of pumping resources, improving the overall system utilization efficiency. Specifically, in this invention, multiple pumps are interconnected with multiple regional pipe networks using an intelligent valve matrix. The central controller can flexibly reconfigure the pump-region connection topology according to real-time demand levels, breaking the limitations of fixed binding. In emergencies, lower-level regional pump sources can be called upon; under normal or low-level conditions, loads can be merged or redundant pumps can be deactivated as needed, ensuring that pumping capacity matches actual demand. This avoids the imbalance of excessive pumping in some areas and insufficient pumping in others.

[0036] Fourth, the system of this invention can achieve energy-efficient operation, effectively reducing the total energy consumption of the system. Specifically, in this invention, when there are no emergency-level areas, the controller reconfigures the connection relationships so that the pumps in operation work within a preset high-efficiency load range as much as possible. For example, multiple low-load areas are merged into the same pump, and redundant pumps are deactivated. In this way, the inefficient "overpowered" operation mode can be effectively avoided, achieving economical operation of the pumping system.

[0037] Fifth, the system of this invention can achieve lifespan balancing and preventative maintenance of the pump cluster, extending the overall lifespan of the equipment. Specifically, in this invention, by recording the cumulative operating time of each pump, role rotation is performed during non-emergency periods when the difference exceeds a threshold, avoiding overuse of some pumps and long-term idleness of others. Simultaneously, the health status of the pumps is determined based on temperature and vibration sensors, prioritizing the disconnection of pumps in deteriorated condition and connecting them to standby pumps. This enables preventative maintenance, extending the mean time between failures (MTBF) and overall lifespan economy of the pump cluster.

[0038] Sixth, the system of this invention possesses self-learning and continuous optimization capabilities, enabling it to adapt to different operating conditions. Specifically, in this invention, after performing topology reconfiguration and load transfer, the controller evaluates the effect of gas concentration changes and records the total system energy consumption for subsequent dynamic adjustment of demand level classification rules. The system can continuously optimize decision parameters based on historical switching effects, becoming increasingly intelligent with use and better adapting to the gas emission characteristics and production rhythms of different mining areas.

[0039] Seventh, this invention limits the frequency converter to output frequency with a linear slope change, and automatically adjusts the slope magnitude using the vacuum degree change rate as feedback. This method does not rely on complex mathematical models, is easy to implement in industrial controllers, has a fast response and strong robustness, and can reduce the implementation threshold of the control system while ensuring smooth switching.

[0040] 2. Other beneficial effects or advantages of the present invention will be described in detail in the specific embodiments. Attached Figure Description

[0041] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0042] in:

[0043] Figure 1 This is a schematic diagram of the layout structure of an intelligent gas extraction system provided in an exemplary embodiment of the present invention;

[0044] Figure 2 This is a flowchart illustrating the steps of the execution method of the central intelligent collaborative controller of an intelligent gas extraction system provided in an exemplary embodiment of the present invention.

[0045] Explanation of the labels in the attached drawings:

[0046] 100-Intelligent gas extraction system; 11-Gas extraction pump; 12-Pipeline network in extraction area; 13-Electrically controlled valve; 14-Central intelligent collaborative controller. Detailed Implementation

[0047] To facilitate a clearer and more accurate understanding of the technical solutions of this invention by those skilled in the art, the existing related technologies and their technical problems will be described in more detail below.

[0048] I. Basic structure and operation mode of gas extraction systems in existing related technologies.

[0049] Currently, most coal mines in China use a "multi-pump, multi-pipeline" layout for their gas drainage systems. Taking a mine with an annual output of 3 million tons as an example, its drainage system includes:

[0050] Six water ring gas extraction pumps, each with a rated power of 400kW and a power frequency of 50Hz, are designed to extract 200 cubic meters per minute.

[0051] Two high negative pressure pipelines (400mm in diameter) are connected to two tunneling faces (referred to as working faces A and B) where coal seam pre-drainage is being carried out.

[0052] Two low negative pressure pipelines (500mm in diameter) are connected to two mining faces (referred to as mining areas C and D) that are currently being mined.

[0053] Each pipeline is connected to the pump via a manual gate valve or a simple electric valve. The correspondence between the pumps and pipelines is fixed when the system is put into operation (for example, pumps #1 and #2 are fixedly connected to high negative pressure pipeline A, pumps #3 and #4 are fixedly connected to mining area C, and pumps #5 and #6 are fixedly connected to mining area D).

[0054] Each pump typically operates at full load at industrial frequency, or occasionally the extraction flow rate is adjusted by workers based on the gas concentration gauge readings by regulating the pump inlet valve opening. When the gas concentration in a certain area exceeds the warning value, the operator will manually start another standby pump and open the corresponding valve to connect to that area; once the concentration decreases, the pump will be manually stopped and the valve closed.

[0055] II. Illustrate the problems existing in the current related technologies with specific examples.

[0056] First, it should be noted that working faces A and B, as two independent coal seam pre-drainage areas, are similar in system configuration and operating status. To control the complexity and length of the example, only working face A will be used as a representative for illustration. The situation of working face B is exactly the same as that of A (e.g., both are in a low-load or pre-drainage state), so it will not be described again in this invention.

[0057] Example 1: Automatic reinforcement is not possible when there is an abnormal gas outburst in the mining area.

[0058] One afternoon, due to roof pressure, a large amount of coal seam gas was released from mining area C, causing the gas concentration in the return airflow of mining area C to rise rapidly from 0.4% to 0.7% (the safety threshold is 0.8%). According to the procedure, the drainage capacity needs to be increased at this time, but the No. 3 and No. 4 pumps currently connected to mining area C are already running at full capacity and cannot be increased in speed. Meanwhile, the gas concentration in mining area D is only 0.2%, and the corresponding No. 5 and No. 6 pumps have a low load rate (about 40%); the pre-drainage tasks of working faces A and B have been basically completed, and the No. 1 and No. 2 pumps are also at low load.

[0059] However, because the connection between the pumps and the area was fixed, and the valves were manually operated, the dispatcher needed to call the workers at each post to first close the air inlet valves of pumps #5 and #6, then open the bypass valve connecting to mining area C, and simultaneously adjust the frequency converter (if applicable)... The entire switching process took approximately 15 minutes. During these 15 minutes, the gas concentration in mining area C exceeded 0.8% and continued to rise, ultimately leading to a power outage and evacuation of personnel from mining area C, causing a production interruption.

[0060] In other words, the existing system cannot automatically identify the emergency level, nor can it dynamically reconfigure the pump-area connection, resulting in the inability to quickly transfer pumping resources (low-load pumps) to the emergency area.

[0061] Example 2: Manual switching caused drastic fluctuations in vacuum level.

[0062] Following the scenario described above, when the worker manually opened the valve connecting pump #5 to mining area C, the vacuum level in the pipeline originally connected to pump #5 in mining area D was 30 kPa, while the vacuum level in the pipeline in mining area C was only 10 kPa. The sudden opening of the valve caused the vacuum level in mining area C to jump instantaneously from 10 kPa to 28 kPa. This massive pressure shock wave propagated along the pipeline, causing the seals of three gas drainage boreholes along the pipeline in mining area C to fail. A large amount of air was drawn into the pipeline, diluting the gas concentration and distorting the monitoring data. Simultaneously, due to the sudden change in air intake, the motor current of pump #5 fluctuated violently, triggering the overload protection trip.

[0063] In other words, the existing system does not have the ability to smoothly transfer loads. Directly connecting or disconnecting high and low negative pressure pipelines will cause sudden fluctuations in vacuum levels, damaging seals and equipment.

[0064] Example 3: Fixed connections lead to energy waste.

[0065] During normal production periods, the gas emission rates in mining areas C and D are low, with gas concentrations stable at 0.3% to 0.4%, requiring a drainage flow rate of only 100 cubic meters per minute per area. However, according to the fixed configuration, mining area C is still being pumped at full capacity by pumps #3 and #4 (total capacity 400 m³ / min), resulting in a situation where the pumps are overloaded and the load rate of each pump is only 25% to 30%, far below their high-efficiency range (usually 60% to 80%). The efficiency of these two pumps has dropped from 92% to 75%, consuming approximately 150 kWh of extra electricity and wasting hundreds of thousands of yuan in electricity costs annually. At the same time, pumps #1 and #2 have been operating for a long time, accumulating more than 5,000 hours of operation, while pumps #5 and #6 are used less frequently due to being on standby, accumulating only 800 hours of operation. This results in an uneven lifespan of the pump group and high early replacement costs.

[0066] In other words, the existing system lacks energy efficiency optimization scheduling and equipment rotation mechanisms, and cannot dynamically merge low-load areas, shut down redundant pumps, or balance pump operating time according to actual needs.

[0067] In summary, existing coal mine gas drainage systems have at least the following technical problems:

[0068] First, there is a lag in regional demand response. The pumping capacity cannot be automatically and safely redeployed from low-demand areas to emergency areas with high gas outbursts, resulting in insufficient localized pumping capacity and posing safety risks.

[0069] Second, the switching process is highly impactful. Sudden pressure changes caused by manual operation or simple valve control can easily damage borehole seals, harm equipment, and affect the stability of pumping.

[0070] Third, low energy efficiency. Fixed connections cause multiple pumps to operate in inefficient zones for extended periods, resulting in energy waste.

[0071] Fourth, uneven equipment lifespan. Some pumps are overused, while others are idle for extended periods, resulting in low overall asset utilization.

[0072] In view of this, the present invention provides a novel solution, namely, an intelligent gas drainage system. The technical concept of the present invention is as follows: multiple gas drainage pumps are interconnected with multiple drainage zones through a reconfigurable valve matrix, and a central controller dynamically classifies the urgency level of drainage needs based on the real-time status and changing trends of gas concentration in each zone; based on this, with zone safety as the highest priority, the drainage pump resources of low-level zones are automatically reallocated to high-level zones, while the pump speed is smoothly adjusted during the switching process to maintain stable vacuum.

[0073] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings.

[0074] like Figure 1 and Figure 2 As shown, the present invention provides an intelligent gas extraction system 100, comprising:

[0075] The reconfigurable gas drainage network includes multiple gas drainage pumps 11, multiple drainage area pipelines 12, and an intelligent valve matrix connecting the multiple gas drainage pumps 11 and the multiple drainage area pipelines 12.

[0076] A distributed sensor network is used to collect the gas concentration and vacuum level of each extraction zone in real time, as well as the load rate and operating status parameters of each gas extraction pump 11.

[0077] The central intelligent collaborative controller 14 is electrically connected to the distributed sensor network, the intelligent valve matrix, and the frequency converters of each gas extraction pump 11.

[0078] The central intelligent collaborative controller 14 is configured to execute:

[0079] Step 1: Based on the relative relationship between the current gas concentration and the safety threshold in each drainage area, and the trend of gas concentration change, classify the drainage needs of each drainage area into emergency level, normal level, or low level.

[0080] Step 2: Based on the demand level of each region, the current load rate of each pump, and the operating status parameters, decide on a dynamic pump-region connection topology reconfiguration scheme. When there is an emergency level region, prioritize switching the pumps connected to the lower level region to the emergency level region.

[0081] Step 3: Based on the topology reconstruction scheme, dynamically switch the pump-area connection relationship by controlling the intelligent valve matrix;

[0082] Step 4: During the dynamic switching process, the gas extraction pump 11 involved in the switching is controlled by the frequency converter, including: gradually changing the speed of the inlet pump and the outlet pump at a smooth rate so that the vacuum fluctuation in the affected area is kept within the preset allowable range.

[0083] Through the above technical solution, firstly, the system of the present invention can achieve rapid and automatic reinforcement of pumping resources to emergency areas, improving safety. Specifically, the central intelligent collaborative controller 14 classifies demand into emergency, normal, and low levels based on the relative relationship and changing trend of the current gas concentration and safety threshold of each pumping area. When an emergency-level area exists, the controller prioritizes switching pumps connected to low-level areas to that emergency area. In this way, the system can automatically identify areas with high gas outburst risk and immediately call upon idle pump resources in a low-demand state without manual intervention, thereby effectively shortening emergency response time and avoiding gas over-limit accidents caused by insufficient pumping capacity.

[0084] Secondly, the system of this invention can avoid drastic fluctuations in vacuum level during the switching process, protecting pipelines and equipment. Specifically, during dynamic switching, the system of this invention requires load transfer control of the input and output pumps via a frequency converter, gradually changing their speeds at a smooth rate, and keeping vacuum level fluctuations in the affected area within a preset allowable range. This eliminates the pressure shocks caused by traditional direct valve switching or sudden changes in pump speed, ensuring a smooth transition of vacuum level in the pumping network during switching, thereby preventing problems such as borehole seal failure, pipeline vibration, and equipment overload tripping.

[0085] Third, the system of this invention enables dynamic, on-demand scheduling of pumping resources, improving the overall system utilization efficiency. Specifically, in this invention, multiple pumps are interconnected with multiple regional pipe networks through an intelligent valve matrix, and the central controller determines the topology reconfiguration scheme based on real-time demand levels to break the fixed binding relationship between pumps and regions. In emergency situations, pumps from lower-level regions can be temporarily relocated to emergency regions; in non-emergency situations, the system can also reconfigure connections based on demand levels to match pumping capacity with the actual needs of the regions, thus avoiding the imbalance of excessive pumping capacity in some regions while insufficient pumping capacity in others.

[0086] Fourth, the system of this invention can achieve closed-loop adaptive control of the switching process, ensuring the maintenance of the preset allowable vacuum level range. Specifically, in this invention, the goal of load transfer control is to keep vacuum fluctuations "within the preset allowable range." That is, while performing smooth speed regulation, the controller continuously monitors the vacuum feedback of the affected area and dynamically adjusts the rotational speed of the inlet / outlet pumps according to the deviation until it stabilizes. In this way, it can ensure that the switching operation does not exceed the safety boundary, satisfying both the speed of emergency deployment and the stability of pipeline operation.

[0087] In one embodiment of the present invention, the specific rules for the central intelligent collaborative controller 14 to classify the extraction and release demand levels can be as follows:

[0088] When the gas concentration in a region has reached or exceeded the safety threshold, it is classified as an emergency level.

[0089] When the gas concentration in a region has not reached the safety threshold, but its concentration shows a continuous upward trend relative to the previous moment and the gap between the current concentration and the safety threshold is narrowing, or the current concentration is close to the safety threshold, it is classified as an emergency level.

[0090] When the gas concentration in a region is far below the safety threshold and there is no upward trend in the concentration, or when the concentration is decreasing, it is classified as a low level.

[0091] Other situations are classified as normal.

[0092] In this implementation, "gas concentration has reached or exceeded the safety threshold," "concentration continues to rise and the gap is narrowing," and "concentration is approaching the safety threshold" are all classified as emergency levels. This allows for the early identification of potential gas over-limit risks, rather than simply waiting for an exceedance to trigger a response. Simultaneously, "far below the safety threshold with no upward trend or currently decreasing" is classified as a low level, ensuring that pump resources in low-level areas can be prioritized for dispatch. In this way, the classification of demand levels has clear and quantifiable criteria, thereby avoiding ambiguous judgments and improving the accuracy and timeliness of emergency response.

[0093] In one embodiment of the present invention, when the central intelligent collaborative controller 14 of the present invention makes a decision on the dynamic topology reconfiguration scheme, it can also execute energy efficiency optimization rules:

[0094] When there are no emergency-level areas, the pump-area connection relationship is reconfigured so that the load rate of the gas drainage pump 11 in operation is as close as possible to its preset high-efficiency load range. This includes merging multiple low-load areas to the same pump to increase its load rate to the high-efficiency range and disabling redundant pumps.

[0095] In this implementation, when there are no emergency-level areas, the connection relationships are reconfigured to bring the pump load rate closer to the high-efficiency range, including merging low-load areas and disabling redundant pumps. This effectively reduces the total system energy consumption while ensuring safety. By merging multiple low-load areas into the same pump, which operates at 60% to 80% of its high-efficiency load range, while disabling other inefficiently operating pumps, energy waste from over-powered pumps is avoided, achieving economical operation of the pumping system.

[0096] In one embodiment of the present invention, when the central intelligent collaborative controller 14 of the present invention makes a decision on the dynamic topology reconfiguration scheme, it can also execute the equipment rotation rule:

[0097] Record the cumulative running time of each gas drainage pump 11. When the difference in the cumulative running time of each pump exceeds a preset threshold, switch the pump with the longest running time to standby during non-emergency periods and connect the healthy pump with the shortest running time.

[0098] In this implementation, the cumulative runtime of each pump is recorded. When the difference exceeds a preset threshold, the pump with the longest runtime is switched to standby during non-emergency periods, and the healthy pump with the shortest runtime is connected. This balances the lifespan of the entire pump group, preventing some pumps from being overused and aging prematurely, while others remain idle for extended periods, resulting in low asset utilization. By rotating pumps, the mean time between failures (MTBF) of the pump group can be extended, reducing the maintenance and replacement costs throughout its lifecycle.

[0099] In one embodiment of the present invention, when the central intelligent collaborative controller 14 of the present invention performs load transfer control, the speed increase rate of the input pump and the speed decrease rate of the output pump are both controlled by ramp signals, and the frequency rise time of the input pump and the frequency fall time of the output pump are dynamically adjusted according to the real-time feedback of the vacuum degree of the pumping and discharging area affected by the switching, so that the vacuum degree fluctuation of the area does not exceed the preset allowable range.

[0100] In this embodiment, both the frequency ramp-up rate of the input pump and the frequency ramp-down rate of the output pump are controlled by ramp signals, and the duration is dynamically adjusted based on real-time feedback of the vacuum level. This enables closed-loop adaptive control of vacuum level fluctuations. Compared to a fixed-rate ramp, dynamic adjustment can correct the speed adjustment in real time based on the deviation between the actual vacuum level and the target vacuum level. This ensures rapid switching while preventing overshoot or oscillation, ensuring that vacuum level fluctuations never exceed the preset allowable range, and improving the robustness and safety of the switching process.

[0101] In one embodiment of the present invention, the intelligent valve matrix of the present invention may include multiple electrically controlled valves 13, which are respectively installed on the air inlet of each gas extraction pump 11, the air outlet of each gas extraction pump 11, and the interconnecting pipelines between the pipeline networks 12 of each extraction area. Each electrically controlled valve 13 is independently controlled by a central intelligent collaborative controller 14.

[0102] In this way, the independently controlled valve matrix enables the system to execute topology reconfiguration schemes flexibly, quickly, and reliably without manual intervention. At the same time, it can also avoid conflicting actions between valves, creating the preconditions for smooth load transfer.

[0103] In one embodiment of the present invention, the distributed sensing network of the present invention may include:

[0104] Gas concentration sensors and vacuum sensors are installed at the pipe inlet of each extraction area;

[0105] Gas concentration sensor, vacuum sensor, flow sensor, temperature sensor and vibration sensor are installed at the inlet and outlet of each gas extraction pump 11.

[0106] In this embodiment, the sensor at the inlet can be used to assess the area's needs; the sensors at the pump inlet and outlet can be used to calculate the load rate, monitor changes in vacuum, and determine the health status (temperature, vibration), thereby supporting multiple functions such as emergency response, energy efficiency optimization, and shift maintenance.

[0107] In one embodiment of the present invention, the central intelligent collaborative controller 14 of the present invention is further configured to: after performing topology reconstruction and load transfer, evaluate the effect of changes in gas concentration in each area based on data collected by the sensor network, and record the total system energy consumption before and after this switchover, for use in the demand level classification rules in subsequent dynamic adjustments.

[0108] In this embodiment, after performing topology reconfiguration and load transfer, the effect of gas concentration changes is evaluated, and the total system energy consumption is recorded for subsequent adjustments to the demand level classification rules. This enables the system of this invention to possess self-learning and continuous optimization capabilities. By recording the actual effects after each switch (gas concentration decrease rate, energy consumption change), the system can dynamically adjust the emergency level trigger threshold or the weight of energy efficiency optimization, thereby adapting to the actual outflow characteristics of different mining areas, becoming increasingly intelligent and efficient with use.

[0109] In one embodiment of the present invention, the central intelligent collaborative controller 14 of the present invention is further configured to: when the health status of a gas extraction pump 11 is determined to be lower than a preset standard based on data collected by a temperature sensor or a vibration sensor, mark the pump as a pump to be maintained, and in the next topology reconfiguration, prioritize its removal from the operating network, while connecting a backup pump to replace its function.

[0110] In this implementation, when a temperature or vibration sensor determines that the health status of a pump is below a preset standard, it is marked as a pump requiring maintenance and will be preferentially disconnected during the next topology reconfiguration, while a backup pump is connected to replace it. This enables preventative maintenance; that is, the system automatically isolates the pump from the operating network before a serious failure occurs, preventing the loss of regional pumping capacity due to sudden failures. Simultaneously, seamless connection to the backup pump ensures the continuity and reliability of the pumping system.

[0111] In one embodiment of the present invention, the smooth rate of the present invention is achieved by the following method: the output frequency of the frequency converter changes according to a fixed linear slope, and when the vacuum degree change rate of the affected area is detected to exceed the preset allowable change rate, the linear slope is automatically reduced until the vacuum degree change rate returns to the allowable range.

[0112] In this embodiment, the inverter output frequency changes with a fixed linear slope, and when the rate of change of vacuum exceeds the allowable rate of change, the linear slope automatically decreases until it recovers. Thus, the fixed reference slope ensures the predictability of speed regulation, while feedback regulation based on the rate of change of vacuum prevents pressure surges. This method does not rely on complex mathematical models, is easy to implement in industrial PLCs, and offers fast response and strong robustness.

[0113] The technical solution of the present invention will be further described below with reference to an exemplary embodiment.

[0114] I. System Configuration.

[0115] A coal mine has the following drainage system installed:

[0116] Pump cluster: 6 water ring gas drainage pumps, numbered P1 to P6, with a rated power of 400kW, a rated speed of 980r / min, and a power frequency of 50Hz. Each pump is equipped with a frequency converter, allowing for stepless speed regulation from 0 to 50Hz.

[0117] Drainage area pipeline network:

[0118] High negative pressure pipeline A (diameter 400mm) connects to working face A (coal seam pre-extraction zone).

[0119] High negative pressure pipeline B (diameter 400mm) connects to working face B (coal seam pre-extraction zone).

[0120] Low negative pressure pipeline C (500mm in diameter) connects to mining area C (longwall face).

[0121] Low negative pressure pipeline D (500mm in diameter) connects to mining area D (longwall face).

[0122] Intelligent valve matrix: 24 electrically controlled valves are installed at the air inlet and outlet of each pump and on the interconnecting pipelines between the main pipelines, all of which are independently controlled by the central controller.

[0123] Distributed sensor networks:

[0124] At the pipeline inlet of each area: install a gas concentration sensor (range 0 to 2%, accuracy ±0.01%) and a vacuum sensor (range -100 to 0 kPa, accuracy ±0.5 kPa).

[0125] Each pump inlet and outlet is equipped with sensors for gas concentration, vacuum, flow rate, temperature (range 0 to 100℃), and vibration (accelerometer).

[0126] Central intelligent collaborative controller: PLC + industrial computer, which collects all sensor data every 6 seconds and executes control logic.

[0127] Initial connection topology (fixed mode):

[0128] P1, P2 → High negative pressure pipeline A (working face A)

[0129] P3, P4 → High negative pressure pipeline B (working face B)

[0130] P5, P6 → Low negative pressure pipeline C (mining area C)

[0131] The low negative pressure pipeline D (mining area D) is not directly connected to the pump and relies on the pipeline from mining area C to be connected via a bypass valve (which is actually a design flaw).

[0132] II. Initial running state (t=0 seconds)

[0133] The system is in a stable state, and the data for each region are shown in Table 1 below:

[0134] Table 1. Data for each region under initial operating conditions

[0135]

[0136] The operating status of each pump is shown in Table 2 below:

[0137] Table 2. Operating status data of each pump under initial operating conditions.

[0138]

[0139] As can be seen from Tables 1 and 2 above, the operating time of P1 and P2 has exceeded 6000 hours, far exceeding that of P3 to P6 (the longest difference is about 5000 hours); the load rate of all pumps is between 68% and 82%, which is in the high-efficiency range (60% to 80%). There is no dedicated pump in mining area D, and its vacuum level is obtained only through a bypass from the pipeline in mining area C, resulting in insufficient actual pumping capacity.

[0140] III. Triggering of abnormal events (t=30 seconds).

[0141] Roof pressure caused a surge in C-gas emissions from the mining area. Sensor data from three consecutive sampling cycles (every 6 seconds) showed a rapid increase in C-gas concentration in the mining area.

[0142] Table 3. Estimation of Gas Concentration and Change Rate in Mining Area

[0143]

[0144] Meanwhile, the vacuum level in mining area C dropped from 14.3 kPa to 13.2 kPa due to insufficient extraction flow. P5 and P6 are already operating at full frequency (50 Hz), with load rates of 95% and 92% respectively, and cannot be increased further.

[0145] IV. Controller execution steps.

[0146] Step 1: Data collection and demand level classification.

[0147] The controller collects data from all sensors every 6 seconds. For each area, it is classified into different levels according to preset rules.

[0148] Mining Area C: Current concentration 0.70%, safety threshold 0.8%, not yet reached but close (87.5%); concentration has been continuously rising in the last 30 seconds (0.52→0.70), and the gap with the threshold has narrowed from 0.28% to 0.10%. According to the rule: "When the gas concentration in a region has not reached the safety threshold, but its concentration shows a continuous upward trend relative to the previous moment and the gap between the current concentration and the safety threshold is narrowing, or the current concentration is close to the safety threshold, it is classified as an emergency level." Therefore, Mining Area C is classified as an emergency level.

[0149] Mining area D: Concentration 0.38%, far below 0.8%, and stable with no upward trend, therefore it is classified as low grade.

[0150] Working surface A: Concentration 0.12%, far below the reference value (pre-evacuation does not require a concentration threshold, and vacuum is the main factor in maintenance), vacuum is stable at 35.2 kPa, therefore, it is judged as low level (the controller uses a vacuum level below the lower limit as the low level for the pre-evacuation zone, which is equivalent here).

[0151] Working surface B: Concentration 0.09%, stable vacuum level, therefore, it is judged to be of low grade.

[0152] Step 2: Topology Reconfiguration Decision.

[0153] The controller performs the following judgments based on the demand level:

[0154] Emergency Priority Rule: An emergency-level area exists (mining area C). The controller scans all pumps in low-level areas: P1, P2 (working face A), P3, and P4 (working face B). It selects the pump with the lowest pipeline impedance (based on pre-calibrated valve positions, P1 has the shortest interconnecting pipeline to mining area C and the lowest impedance), prioritizing switching P1 to mining area C. Simultaneously, a health status check is performed: P1 vibration 1.2 mm / s (threshold 2.0 mm / s), temperature 58℃ (threshold 75℃), indicating good health and availability for dispatch.

[0155] Energy efficiency optimization rules: There is currently an emergency level, so energy efficiency optimization is suspended (safety first).

[0156] Equipment rotation rules: The controller recorded a cumulative duration of 6200 hours for P1 and only 1800 hours for P3, a difference of 4400 hours, exceeding the preset threshold (200 hours). In this switchover, P1 was moved out of its original area and connected to mining area C, which effectively achieved the effect of rotation (other pumps can subsequently take over working face A).

[0157] Decision: Disconnect P1 from working face A and reconnect it to mining area C. Other pumps remain unchanged. Valve command generated: Close the inlet valve between P1 and high negative pressure pipeline A, and open the bypass valve between P1 and low negative pressure pipeline C.

[0158] Step 3: Perform dynamic switching.

[0159] The controller sends commands to the intelligent valve matrix to change the valve status. At the same time, load transfer control is initiated.

[0160] Step 4: Smooth load transfer control.

[0161] Current status: Mining area C is currently being pumped by P5 (50Hz, 95% load) and P6 (50Hz, 92%), with a vacuum of 13.2 kPa (target to maintain 15 kPa). P1 was originally connected to high negative pressure pipeline A (35 kPa vacuum), which needs to be smoothly connected to the low pressure system.

[0162] Control process:

[0163] 1. Pre-synchronization stage:

[0164] The controller first lowers the frequency of the P1 inverter from the current 48Hz (original operating frequency) to 25Hz (close to the speed corresponding to the vacuum level on the low-voltage side). The lowering rate uses a ramp signal with a fixed slope of 5Hz / second, taking (48-25) / 5=4.6 seconds. During this period, the vacuum level at the P1 outlet is monitored, which decreases from 35kPa to approximately 18kPa (close to 13.2kPa in mining area C, but still slightly higher).

[0165] 2. Entry Phase:

[0166] When the frequency of P1 drops to 25Hz, the valve between P1 and mining area C is opened. At this time, the vacuum degree of P1 outlet is 18kPa, which is slightly higher than that of mining area C (13.2kPa), and there is a slight risk of backflow. Therefore, the controller immediately increases the speed of P1 by ramping up the frequency (slope 3Hz / second) while monitoring the vacuum degree of mining area C.

[0167] The frequency ramp-up time of the input pump is dynamically adjusted based on real-time feedback of the vacuum level. The target vacuum level is set at 15 kPa, with an allowable fluctuation of ±1 kPa. When the vacuum level in mining area C starts to rise from 13.2 kPa, the controller adjusts the frequency ramp-up rate: if the rate of increase exceeds the allowable rate of change (preset to 0.8 kPa / second), the ramp rate is automatically reduced. In practice, the frequency ramp-up rate is set to an initial ramp rate of 3 Hz / second, and the vacuum level change is checked every 0.5 seconds.

[0168] During the frequency increase process, the load on P1 gradually increased, and the vacuum level in mining area C slowly rose to 14.1 kPa (taking 4 seconds, the frequency rose to 37 Hz).

[0169] 3. Load handover phase:

[0170] When P1 handles approximately 30% of the total regional load (estimated by a flow sensor; P1 inlet flow rate is approximately 60 m³ / min, and the total regional demand is approximately 200 m³ / min), the frequencies of P5 and P6 are reduced (pumps are switched off). Frequency reduction uses a ramp signal with a preset ramp rate of 2 Hz / second.

[0171] Meanwhile, continue to increase the P1 frequency. During the handover process, maintain the vacuum level fluctuation in mining area C within ±1 kPa. The controller compares the deviation between the current vacuum level and the target 15 kPa every 0.2 seconds and uses PID control: if the vacuum level is below 14 kPa, pause the cut-out pump to reduce its frequency and increase the frequency increase rate of the inlet pump; if the vacuum level is above 16 kPa, accelerate the frequency reduction of the cut-out pump.

[0172] After approximately 12 seconds, the frequency of P5 decreased from 50Hz to 38Hz (load rate decreased to 60%), P6 decreased from 50Hz to 35Hz (load rate 55%), and the frequency of P1 increased to 45Hz (load rate 70%). The vacuum level in mining area C stabilized at 15.1kPa.

[0173] 4. Cutting Completed and Final Adjustments:

[0174] When the load rates of P5 and P6 are below 30% (approximately 25Hz), the controller closes the valves connecting them to mining area C, completely disconnecting them. Both pumps then go into standby or reserve mode.

[0175] P1 continued to fine-tune the frequency to 46Hz, maintaining the load rate at around 70% and stabilizing the vacuum level in mining area C at 15.0 kPa. The entire switching process, from start to stabilization, took approximately 25 seconds.

[0176] Vacuum fluctuation record during the period: The maximum fluctuation was from 13.2 kPa to 16.1 kPa (overshoot +1.1 kPa), which lasted for about 1.5 seconds before returning to within 15 kPa, which is within the preset allowable range (±1.5 kPa).

[0177] Step 5: Effect evaluation and self-optimization.

[0178] The controller will re-collect data 30 seconds after the switch is completed.

[0179] The concentration of C gas in the mining area started to decrease from 0.70%, dropped to 0.58% after 30 seconds, dropped to 0.49% after 60 seconds, and finally stabilized at around 0.45% (below the safety threshold).

[0180] Total system energy consumption: Before the switch, the total power of P1 to P6 was (400*0.78+400*0.75+400*0.70+400*0.68+400*0.95+400*0.92)=approximately (312+300+280+272+380+368)=1912kW; After the switch, the power of P1 increased to 310kW (0.775), P5 and P6 were shut down, and P2, P3 and P4 remained in their original state (but only P2 remained on working face A, and its load rate increased from 75% to 85%, with a power of 340kW). The new total power = 310(P1)+340(P2)+280(P3)+272(P4)=1202kW, saving approximately 710kW, and significantly improving energy efficiency.

[0181] The controller records energy consumption data before and after this switch and stores the correspondence between "emergency level trigger threshold and response plan" for subsequent dynamic adjustment of demand level classification rules (such as fine-tuning the condition of triggering an emergency when the threshold of 85% is close to the safety threshold to 87%).

[0182] Step 6: Equipment rotation and health maintenance.

[0183] Since P1 has been running for 6200 hours, while P3 has only run for 1800 hours, the controller will implement a rotation system during subsequent non-emergency periods (such as the next shift's production schedule): the roles of P1 and P3 will be swapped, with P3 connected to mining area C and P1 put on standby and scheduled for maintenance. Simultaneously, when the vibration sensor detects that the vibration value of P5 exceeds 2.5 mm / s (the preset health threshold is 2.0 mm / s), the controller will mark this pump as needing maintenance, prioritize its disconnection in the next topology reconfiguration, and connect it to P4 as a replacement.

[0184] Step 7: Energy efficiency optimization scenario example.

[0185] During a particular shift, the gas concentration in all mining areas was at a low level (Mining Area C 0.35%, Mining Area D 0.30%, and working faces A and B had already completed pre-drainage and did not require continuous high negative pressure). The controller entered energy efficiency optimization mode and reconfigured the topology: Mining Areas C and D were connected to the same pump (for example, P1 was connected to both areas simultaneously, via valve time-sharing or flow-diversion), P2, P3, and P4 were shut down, and only P1 and P5 (standby) were used, increasing the load rate of P1 from 45% to 78%, entering the high-efficiency zone, and reducing the total system energy consumption by approximately 40%.

[0186] In the above exemplary embodiments, it is understood that, firstly, during the switching process, the controller sends switching commands to the P1 intake valve, bypass valve, and P5 / P6 intake valves respectively, and all valves operate within 2 seconds. Secondly, all area pipeline inlets and pump inlets and outlets are equipped with corresponding sensors to ensure the integrity of data acquisition. For example, during load handover, flow sensors are used to estimate the load proportion borne by each pump. Finally, the inverter output frequency changes at a fixed linear slope (3Hz / second for up-frequency reference and 2Hz / second for down-frequency reference). When the vacuum change rate exceeds 0.8kPa / second, the slope is automatically halved until it recovers.

[0187] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An intelligent gas extraction system, characterized in that, include: A reconfigurable gas drainage network includes multiple gas drainage pumps, multiple drainage area pipelines, and an intelligent valve matrix connecting the multiple gas drainage pumps and the multiple drainage area pipelines. A distributed sensor network is used to collect in real time the gas concentration and vacuum level of each extraction area, as well as the load rate and operating status parameters of each gas extraction pump. The central intelligent collaborative controller is electrically connected to the distributed sensor network, the intelligent valve matrix, and the frequency converters of each gas extraction pump. The central intelligent collaborative controller is configured to execute: Based on the relative relationship between the current gas concentration and the safety threshold in each drainage area, and the trend of gas concentration change, the drainage needs of each drainage area are divided into emergency level, normal level, or low level. Based on the demand level of each region, the current load rate of each pump, and the operating status parameters, a dynamic pump-region connection topology reconfiguration scheme is determined. Among them, when there is an emergency level region, pumps connected to the lower level region are preferentially switched to the emergency level region. According to the topology reconstruction scheme, the pump-area connection relationship is dynamically switched by controlling the intelligent valve matrix; During the dynamic switching process, the frequency converter controls the load transfer of the gas extraction pumps involved in the switching, including: gradually changing the speed of the inlet pump and the outlet pump at a smooth rate so that the vacuum fluctuation in the affected area is kept within a preset allowable range.

2. The intelligent gas extraction system as claimed in claim 1, wherein, The specific rules for classifying extraction and release demand levels by the central intelligent collaborative controller are as follows: When the gas concentration in a region has reached or exceeded the safety threshold, it is classified as an emergency level. When the gas concentration in a region has not reached the safety threshold, but its concentration shows a continuous upward trend relative to the previous moment and the gap between the current concentration and the safety threshold is narrowing, or the current concentration is close to the safety threshold, it is classified as an emergency level. When the gas concentration in a region is far below the safety threshold and there is no upward trend in the concentration, or when the concentration is decreasing, it is classified as a low level. Other situations are classified as normal.

3. The intelligent gas extraction system as claimed in claim 1, wherein, When the central intelligent collaborative controller makes a decision on the dynamic topology reconfiguration scheme, it also executes energy efficiency optimization rules: When there are no emergency zones, reconfigure the pump-zone connection relationship so that the load rate of the gas drainage pumps in operation is as close as possible to their respective preset high-efficiency load range. This includes merging multiple low-load zones to the same pump to increase its load rate to the high-efficiency range and disabling redundant pumps.

4. The intelligent gas extraction system according to claim 1, characterized in that, When the central intelligent collaborative controller makes a decision on the dynamic topology reconfiguration scheme, it also executes the equipment rotation rule: Record the cumulative runtime of each gas drainage pump. When the difference in cumulative runtime of each pump exceeds a preset threshold, switch the pump with the longest runtime to standby during non-emergency periods and connect the healthy pump with the shortest runtime.

5. The intelligent gas extraction system according to claim 1, characterized in that, When the central intelligent collaborative controller performs load transfer control, the speed increase rate of the input pump and the speed decrease rate of the output pump are both controlled by ramp signals. Furthermore, the frequency rise time of the input pump and the frequency fall time of the output pump are dynamically adjusted in real time based on the vacuum level feedback of the pumping and discharging area affected by the switching, so that the vacuum level fluctuation in the area does not exceed the preset allowable range.

6. The intelligent gas extraction system according to claim 1, characterized in that, The intelligent valve matrix includes multiple electrically controlled valves, which are respectively installed at the air inlet of each gas extraction pump, the air outlet of each gas extraction pump, and the interconnecting pipelines between the pipeline networks of each extraction area. Each electrically controlled valve is independently controlled by the central intelligent collaborative controller.

7. The intelligent gas extraction system according to claim 1, characterized in that, The distributed sensor network includes: Gas concentration sensors and vacuum sensors are installed at the pipe inlet of each extraction area; Gas concentration sensor, vacuum sensor, flow sensor, temperature sensor and vibration sensor are installed at the inlet and outlet of each gas extraction pump.

8. The intelligent gas extraction system according to claim 1, characterized in that, The central intelligent collaborative controller is also configured to: after performing topology reconstruction and load transfer, evaluate the effect of gas concentration changes in each area based on data collected by the sensor network, and record the total system energy consumption before and after the switch, for use in the demand level classification rules in subsequent dynamic adjustments.

9. The intelligent gas extraction system according to claim 1, characterized in that, The central intelligent collaborative controller is also configured to: when the health status of a gas drainage pump is determined to be lower than a preset standard based on data collected by a temperature sensor or vibration sensor, mark the pump as a pump to be maintained, and prioritize its removal from the operating network during the next topology reconfiguration, while connecting a backup pump to replace its function.

10. The intelligent gas extraction system according to claim 1, characterized in that, The smooth rate is achieved by the following method: the inverter output frequency changes according to a fixed linear slope, and when the vacuum degree change rate in the affected area is detected to exceed the preset allowable change rate, the linear slope is automatically reduced until the vacuum degree change rate returns to the allowable range.

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