System for controlling hydraulic support through servo electric cylinder

Abstract

The utility model discloses a system for controlling a hydraulic support by using a servo electric cylinder, and the system comprises a sensor module which comprises a plurality of sensors which are respectively installed on the hydraulic support and the servo electric cylinder, and the sensors are used for collecting the working parameters of the hydraulic support and the servo electric cylinder; the data processing module is connected with the sensor module, generates a control instruction for controlling the servo electric cylinder according to the received working parameters of the hydraulic support, and corrects the action of the servo electric cylinder according to the received working parameters of the servo electric cylinder; and the controller module is connected with the data processing module and transmits a control instruction to the driving module, so that the driving module drives the servo electric cylinder to act. According to the scheme, the working parameters of the servo electric cylinder are collected in real time, the operation action of the servo electric cylinder is corrected, and then closed-loop control is conducted on the servo electric cylinder, so that the system can find and correct deviation in the action process of the hydraulic support in time, stable operation of equipment is ensured, and the safety performance is improved.

Description

Technical Field

[0001] This application generally relates to the field of hydraulic support control technology. More specifically, this application relates to a system that uses a servo electric cylinder to control a hydraulic support. Background Technology

[0002] Hydraulic supports, as key equipment used in underground mining operations such as coal mines to support the roof and maintain the safety of the working space, have a crucial impact on the safety and efficiency of mining operations due to their performance and control precision. Traditional hydraulic supports mostly use hydraulic systems for control; however, hydraulic systems suffer from problems such as slow response speed, limited control precision, susceptibility to leakage, and high maintenance costs. With the development of industrial automation and intelligence, higher requirements are being placed on the control precision and response speed of hydraulic supports.

[0003] Servo electric cylinders, as a new type of linear drive device, possess advantages such as high precision, high response speed, zero leakage, and simple maintenance, making them highly promising for the control of hydraulic supports. However, currently, there is a lack of a systematic and effective control method for hydraulic supports using servo electric cylinders to fully leverage their advantages and achieve efficient and precise control of hydraulic supports.

[0004] In view of this, there is an urgent need to provide a system that uses servo electric cylinders to control hydraulic supports, so as to achieve precise control and intelligent management of the hydraulic support's movements. Utility Model Content

[0005] To at least address the technical problems mentioned above, this application proposes a system for controlling a hydraulic support using a servo electric cylinder, which can efficiently and precisely control the hydraulic support.

[0006] This application provides a system for controlling a hydraulic support using a servo electric cylinder, comprising: a sensor module including multiple sensors respectively mounted on the hydraulic support and the servo electric cylinder, the sensors being used to collect operating parameters of the hydraulic support and the servo electric cylinder; a data processing module connected to the sensor module, which generates control commands for controlling the servo electric cylinder based on the received operating parameters of the hydraulic support, and corrects the action of the servo electric cylinder based on the received operating parameters of the servo electric cylinder; and a controller module connected to the data processing module, which transmits the control commands to a drive module, causing the drive module to drive the servo electric cylinder to move.

[0007] In some embodiments, the data processing module adjusts the control command based on the deviation between the actual operating parameters and the target parameters of the servo cylinder, thereby correcting the action of the servo cylinder.

[0008] In some embodiments, the drive module feeds back the actual operating parameters of the servo electric cylinder to the data processing module.

[0009] In some embodiments, the data processing module includes a signal generation unit, which is used to generate a drive signal containing the target position, target speed and acceleration of the servo cylinder according to the control command, and the drive module drives the servo cylinder to move according to the drive signal.

[0010] In some embodiments, the sensor module includes one or more of a tilt sensor, a displacement sensor, and an encoder.

[0011] In some embodiments, the system further includes a ground control center module, which is connected to the data processing module.

[0012] In some embodiments, the system further includes a human-computer interaction interface connected to the data processing module and used to input control parameters and display data.

[0013] In some embodiments, the system further includes a leakage current detection module, which is connected to the data processing module.

[0014] In some embodiments, the system further includes a remote control module, which includes a remote controller and a receiver connected to each other, and the receiver is connected to the data processing module.

[0015] In some embodiments, the system further includes a debugging and calibration module connected to the data processing module for performing initial calibration and periodic verification of the sensor to ensure data acquisition accuracy.

[0016] The system for controlling hydraulic supports using servo electric cylinders, as described above, replaces the traditional hydraulic system with servo electric cylinders to control the hydraulic supports. Leveraging the high precision and high response speed of the servo electric cylinders, precise control of the hydraulic support's movements is achieved, improving the working accuracy and efficiency of the hydraulic support. Furthermore, this solution also collects the working parameters of the servo electric cylinders in real time and corrects their movements, enabling timely detection and correction of deviations during the hydraulic support's operation, ensuring stable operation and improving the reliability and safety of the hydraulic support. Attached Figure Description

[0017] The above and other objects, features, and advantages of exemplary embodiments of this application will become readily understood by reading the following detailed description with reference to the accompanying drawings. In the drawings, several embodiments of this application are illustrated by way of example and not limitation, and the same or corresponding reference numerals denote the same or corresponding parts, wherein:

[0018] Figure 1This application illustrates a system for controlling a hydraulic support using a servo electric cylinder, according to an embodiment of the present application.

[0019] Figure 2 An embodiment of a system for controlling a hydraulic support using a servo electric cylinder, according to an embodiment of this application, is shown;

[0020] Figure 3 This application illustrates an embodiment of using a servo electric cylinder to control a hydraulic support.

[0021] Figure 4 This application illustrates an embodiment of using a servo electric cylinder to control a hydraulic support.

[0022] Figure 5 An embodiment of the present application is shown, which uses a servo electric cylinder to control a hydraulic support.

[0023] In the diagram: 100. A system that uses a servo electric cylinder to control a hydraulic support;

[0024] 101. Sensor Module; 102. Data Processing Module; 103. Drive Module; 104. Controller Module; 105. Ground Control Center Module; 106. Leakage Detection Module; 107. Remote Control Module; 108. Debugging and Calibration Module;

[0025] 1021, Signal generation unit; 1051, Human-computer interaction interface. Detailed Implementation

[0026] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0027] It should be understood that the terms "comprising" and "including" used in the specification and claims of this application indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0028] It should also be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application. As used in this specification and claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used in this specification and claims refers to any combination and all possible combinations of one or more of the associated listed items, and includes such combinations.

[0029] As used in this specification and claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrase "if determined" or "if [described condition or event] is detected" may be interpreted, depending on the context, as "once determined," "in response to determination," "once [described condition or event] is detected," or "in response to detection of [described condition or event]."

[0030] The specific embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0031] like Figure 1 As shown, in some embodiments, a system 100 for controlling a hydraulic support using a servo electric cylinder includes: a sensor module 101, which includes multiple sensors respectively mounted on the hydraulic support and the servo electric cylinder, the sensors being used to collect the operating parameters of the hydraulic support and the servo electric cylinder; a data processing module 102, which is connected to the sensor module, generates control commands for controlling the servo electric cylinder based on the received operating parameters of the hydraulic support, and corrects the action of the servo electric cylinder based on the received operating parameters of the servo electric cylinder; and a controller module 104, which is connected to the data processing module, transmits the control commands to a drive module, causing the drive module 103 to drive the servo electric cylinder to move.

[0032] The system 100 for controlling a hydraulic support using a servo electric cylinder in this solution includes a sensor module 101, a data processing module 102, a drive module 103, and a controller module 104. Specifically, the sensor module 101 consists of sensors installed at multiple key locations on the hydraulic support and the servo electric cylinder. Each sensor is used to collect real-time operating parameters of the hydraulic support and the servo electric cylinder. These parameters include the displacement and angle of the hydraulic support's top beam, the attitude of the shield beam, and the real-time position and speed of the servo electric cylinder. By setting up these sensors, the system can accurately acquire various state parameters of the hydraulic support and the servo electric cylinder during operation, providing a data foundation for subsequent precise control.

[0033] The data processing module 102 is connected to the sensor module 101. It receives the operating parameters of the hydraulic support collected by the sensor, preprocesses the operating parameters of the hydraulic support using a preset control model and algorithm, and then calculates the control commands for controlling the servo cylinder by combining the current operating state of the hydraulic support and the target parameters. In addition, the data processing module 102 also corrects the action of the servo cylinder according to the received operating parameters of the servo cylinder, thereby ensuring that the hydraulic support can perform precise actions according to the predetermined working requirements.

[0034] The controller module 104 is connected to the data processing module 102 and transmits control commands to the drive module 103. The drive module 103 then drives the servo cylinder according to the control commands generated by the data processing module 102, precisely controlling the servo cylinder's position, speed, and movement mode. Furthermore, during the driving process, the drive module 103 can monitor the actual operating parameters of the servo cylinder in real time and feed these parameters back to the data processing module 102.

[0035] Those skilled in the art will understand that the drive module 103 in the above solution can be an independent functional module or a functional component of a servo electric cylinder. The solution in this application does not limit the specific form of the drive module.

[0036] Those skilled in the art will also understand that the data processing module in this application can be a programmable logic controller (PLC). Furthermore, to ensure better signal transmission, the data processing module and other functional modules in this solution are connected via a controller area network (CAN).

[0037] This application's solution replaces the traditional hydraulic system with a servo electric cylinder, leveraging its high precision and high response speed to achieve accurate control of the hydraulic support's movements, significantly improving work accuracy and efficiency. Furthermore, this solution collects the servo electric cylinder's operating parameters in real time and corrects its movements, thus implementing closed-loop control. This allows the system to promptly detect and correct deviations during the hydraulic support's operation, ensuring stable equipment operation and improving safety performance.

[0038] In one specific implementation, the drive module feeds back the actual operating parameters of the servo electric cylinder to the data processing module.

[0039] In this scheme, when the servo electric cylinder is in motion, the drive module obtains the actual operating parameters of the servo electric cylinder, and then feeds the parameters back to the data processing module via the control module. The data processing module re-optimizes the control commands for the servo electric cylinder based on the actual operating parameters and template parameters, thereby realizing closed-loop control of the servo electric cylinder.

[0040] In one specific implementation, the data processing module 102 adjusts the control commands based on the deviation between the actual operating parameters and the target parameters of the servo electric cylinder, thereby correcting the action of the servo electric cylinder. The drive module 103 feeds back the actual operating parameters of the servo electric cylinder to the data processing module 102.

[0041] In this scheme, the drive module 103 monitors the actual operating parameters of the servo cylinder in real time, such as position, speed, and load force, and feeds these parameters back to the data processing module 102. This real-time feedback mechanism provides crucial data support for closed-loop control, enabling the data processing module 102 to understand the actual operating status of the servo cylinder in a timely manner and make accurate control decisions. The processing module compares and analyzes the actual operating parameters of the servo cylinder with the target parameters to obtain the deviation value. After receiving the actual operating parameters fed back by the drive module 103, the processing module compares and analyzes them with the target parameters, optimizes the control commands, and causes the servo cylinder to act according to the optimized control commands.

[0042] This solution achieves precise control of the servo cylinder's movements by monitoring the actual operating parameters of the servo cylinder in real time and adjusting the control commands according to the deviation value. This improves the working accuracy of the hydraulic support and ensures that the hydraulic support moves precisely according to the predetermined working requirements.

[0043] In one specific implementation, the data processing module 102 includes a signal generation unit, which generates a drive signal containing the target position, target speed and acceleration of the servo electric cylinder according to the control command, and the drive module 103 drives the servo electric cylinder to move according to the drive signal.

[0044] In the above scheme, the data processing module 102 not only processes and analyzes the collected hydraulic support operating parameters, but also includes a signal generation unit. This signal generation unit generates signals for controlling the servo cylinder's movement based on control commands. Specifically, after processing and analyzing the hydraulic support's operating parameters, the data processing module 102 calculates the target position, target velocity, and acceleration of the servo cylinder based on a preset control model and algorithm. The signal generation unit then generates a drive signal containing these target parameters based on these calculation results.

[0045] It is worth noting that the drive signal is a standardized electrical signal, the format and parameters of which are designed to be recognizable and responsive to by the servo cylinder driver, such as analog voltage signals, pulse width modulation (PWM) signals, or digitally encoded signals. The drive signal carries the position, speed, and acceleration information that the servo cylinder needs to achieve. After receiving this signal, the drive module 103 converts it into a specific current or voltage output to drive the servo cylinder to perform corresponding actions, such as extending or retracting, and moving at a specific speed and acceleration.

[0046] When the servo cylinder receives a drive signal from the driver, its internal motor begins to move according to the parameters indicated by the signal. For example, if the drive signal indicates that the servo cylinder needs to extend quickly to a specific position, the driver will output a corresponding high-frequency pulse signal or high-voltage signal, causing the motor to rotate at high speed, thereby driving the servo cylinder to extend quickly.

[0047] It is also worth noting that the drive signal generated by the signal generation unit is transmitted to the drive module 103 via a data bus or other communication interface. During transmission, the integrity and accuracy of the signal are crucial, as any loss or distortion of the signal can lead to errors or instability in the servo cylinder's operation. Therefore, this system employs a communication protocol with high anti-interference capability and reliability, such as the CAN bus protocol, to ensure that the drive signal reaches the drive module 103 accurately.

[0048] In this solution, the drive signal generated by the signal generation unit includes the precise target position, target velocity, and acceleration information of the servo electric cylinder. The drive module 103 can drive the servo electric cylinder to perform actions based on these precise signals, thereby achieving precise control of various parts of the hydraulic support. This precise control enables the hydraulic support to better adapt to roof pressure changes in complex downhole environments, accurately complete actions such as support and movement, and improve the safety and efficiency of mining operations.

[0049] In one specific implementation, sensor module 101 includes one or more of tilt sensors, displacement sensors, and encoders.

[0050] In this solution, the sensor module 101 plays a fundamental and crucial role in the system. It includes one or more of tilt sensors, displacement sensors, and encoders. These sensors are precisely installed at various key locations on the hydraulic support to comprehensively and accurately collect multiple key parameters of the hydraulic support and its servo cylinders during operation. Specifically, the tilt sensor, installed on the hydraulic support, primarily monitors the attitude changes of components such as the shield beam in real time, i.e., measuring their tilt angle relative to the horizontal plane. This is crucial for ensuring the hydraulic support maintains stable support and correct attitude in complex downhole environments. The displacement sensor, installed on components such as the top beam of the hydraulic support, monitors the displacement of the top beam, including changes in height during ascent and descent. Accurate displacement data helps the control system understand the position status of the top beam in a timely manner. The encoder is typically installed on the servo cylinder to monitor parameters such as the real-time position, speed, and direction of movement of the servo cylinder. This information is essential for achieving precise control and feedback control of the servo cylinder.

[0051] The disclosed solution, through the configuration of multiple sensors, enables the system to comprehensively and accurately acquire operational status information of the hydraulic support and its servo electric cylinder from multiple dimensions. This data provides rich foundational information for subsequent data processing and control command generation, ensuring that the control system has a comprehensive understanding of the equipment's operating status.

[0052] like Figure 2 As shown, in a specific scheme, the system also includes a ground control center module 105, which is connected to the data processing module 102.

[0053] In this solution, the system 100, which uses servo electric cylinders to control hydraulic supports, includes a ground control center module 105 connected to a data processing module 102. This ground control center module 105, via a wired or wireless communication network, together with the downhole controller module 104, forms a remote monitoring and control system. Specifically, the ground control center module 105 is equipped with a high-performance computer, data storage devices, and specialized control software, enabling centralized control and monitoring of the downhole hydraulic supports and their servo electric cylinders. Personnel on the ground can monitor the operating status of the hydraulic supports in real time and send control commands to the downhole controller module 104, achieving remote operation and management. This design enables remote control of the downhole hydraulic supports from the ground, eliminating the need for operators to go down into the well, simplifying processes, and improving efficiency.

[0054] In one specific implementation, the system also includes a human-machine interface connected to the data processing module, used for inputting control parameters and displaying data.

[0055] In the aforementioned scheme, the system also includes a human-machine interface (HMI) connected to the controller. This HMI allows operators to manually input control parameters and issue control commands to the servo cylinders. Furthermore, the HMI displays data such as relevant operating parameters detected by sensor module 101. Simultaneously, the interface displays real-time system operating data and status information, enabling operators to monitor the operation of the hydraulic supports and servo cylinders at any time and promptly identify potential problems or anomalies. This provides operators with a comprehensive view of system information, facilitating timely understanding of equipment operating status, enabling remote diagnosis and fault handling, and ensuring stable system operation. Additionally, when a system malfunctions or malfunctions, the HMI can promptly display fault alarm information, including the fault location, type, and possible causes. This provides valuable guidance to operators, enabling them to quickly locate the fault point, shorten troubleshooting time, and improve system availability and reliability.

[0056] This solution incorporates a human-machine interface, enabling operators to input and adjust control parameters through a simple and clear interface.

[0057] like Figure 3 As shown, in one specific implementation, the system further includes a leakage current detection module 106, which is connected to the data processing module 102.

[0058] In this solution, the leakage current detection module 106 is communicatively connected to the data processing module and is responsible for real-time monitoring of leakage current in the entire control system and its related circuits. Once leakage current is detected, an alarm signal is quickly sent to the controller module 104. Specifically, the leakage current detection module 106 in this solution includes a leakage current signal acquisition circuit, a signal processing circuit, and an alarm circuit. More specifically, the leakage current signal acquisition circuit includes a voltage detection unit and a current detection unit. The voltage detection unit is used to detect the voltage in the circuit. When the voltage exceeds the set normal range, it can be determined that there may be a leakage current. For example, it detects the voltage between the equipment casing and ground. Under normal circumstances, this voltage should be close to zero. If the voltage rises, there may be a leakage current. The current detection unit is used to detect the leakage current in the circuit. It usually uses a zero-sequence current transformer (ZSCT). The circuit to be detected (such as the three-phase power line and the neutral line) passes through the toroidal core of the ZSCT simultaneously. Under normal circumstances, the vector sum of the three-phase currents cancels out the vector sum of the neutral line current, and the output of the ZSCT is zero. When leakage occurs, the leakage current will generate an induced current in the ZSCT, thereby detecting the leakage.

[0059] The signal processing circuit includes an amplifier circuit, a filter circuit, and a comparator circuit. The amplifier circuit amplifies the weak leakage signal to a suitable voltage or current level, ensuring accurate signal processing. The filter circuit removes noise and interference components, such as high-frequency interference, from the acquired leakage signal. The filter circuit can employ passive or active filtering to ensure the purity and stability of the output signal, improving the accuracy of leakage detection. The comparator circuit compares the amplified leakage signal with a preset threshold. When the leakage signal exceeds the threshold, the comparator circuit outputs a trigger signal, indicating a leakage has occurred. This trigger signal activates the alarm circuit and sends an alarm signal to the controller module.

[0060] The alarm circuit can be an audible and visual alarm device. When a leakage current is detected, the alarm circuit will be activated, emitting an audible and visual alarm signal to alert the operator. The audible and visual alarm device can include a buzzer, an alarm light, etc. The buzzer emits a continuous or intermittent sound, and the alarm light flashes or remains constantly lit, so as to alert the operator in different environments.

[0061] In summary, the leakage current detection module in this solution is connected to the data processing module via a communication circuit, enabling the real-time transmission of the leakage current signal to the data processing module upon detection. Upon receiving the leakage current signal, the data processing module performs corresponding processing and analysis to further confirm the leakage situation and take appropriate control measures, such as cutting off the power supply or stopping equipment operation, to ensure the safety of equipment and personnel.

[0062] like Figure 4 As shown, in one specific implementation, the system further includes a remote control module 107, which includes a remote controller and a receiver connected to each other, and the receiver is connected to the data processing module 120.

[0063] In this solution, the system integrates a remote control module 107, which consists of an interconnected remote controller and a receiver, with the receiver connected to a data processing module. The remote controller, acting as the operating terminal, is equipped with various control buttons or an interface, allowing operators to input control commands such as start, stop, and adjustment of operating parameters via buttons or touchscreen. The receiver connects wirelessly to the remote controller and directly to the controller module 104. After the operator issues a command via the remote controller, the receiver receives it instantly and converts it into an electrical signal, transmitting it to the controller module 104. The controller module 104 parses the command, generates corresponding control commands, and enables remote control of the hydraulic support. This design empowers operators with remote control capabilities, eliminating the need to be physically present at the equipment site, simplifying the operation process, improving work efficiency, and making it particularly suitable for complex or hazardous downhole environments.

[0064] like Figure 5 As shown, in one specific implementation, the system also includes a debugging and calibration module 108 connected to the data processing module, used to perform initial calibration and periodic verification of the sensor to ensure data acquisition accuracy.

[0065] In this solution, the system is equipped with a debugging and calibration module 108 connected to the data processing module, focusing on the initial calibration and periodic verification of the sensor to ensure the accuracy of data acquisition. Initial calibration is performed during sensor installation or the first run of the system. By comparing the data acquired by the sensor with data provided by standard measuring equipment, the deviation is calculated and calibration parameters are adjusted to ensure the accuracy and reliability of the initial data. Furthermore, periodic verification regularly verifies the sensor's accuracy, promptly identifying and addressing performance degradation or data deviation issues caused by environmental interference, long-term operation, or component aging.

[0066] This solution incorporates a debugging and calibration module 108, which effectively improves the system's control accuracy and provides a reliable information source for the controller. This ensures that the generated control commands are accurate and error-free, achieving high-precision control of the hydraulic support and meeting the stringent requirements for precise control in fields such as coal mining.

[0067] While numerous embodiments of this application have been shown and described herein, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Many modifications, alterations, and alternatives will arise for those skilled in the art without departing from the spirit and intent of this application. It should be understood that various alternatives to the embodiments of this application described herein may be employed in the practice of this application. The appended claims are intended to define the scope of protection of this application and therefore cover equivalents or alternatives within the scope of these claims.

Claims

1. A system for controlling a hydraulic support using a servo electric cylinder, characterized in that, include: The sensor module includes multiple sensors respectively mounted on the hydraulic support and the servo cylinder, the sensors being used to collect the operating parameters of the hydraulic support and the servo cylinder; A data processing module, connected to the sensor module, generates control commands for controlling the servo cylinder based on the received working parameters of the hydraulic support, and corrects the action of the servo cylinder based on the received working parameters of the servo cylinder. as well as The controller module is connected to the data processing module and transmits the control commands to the drive module, so that the drive module drives the servo electric cylinder to move.

2. The system according to claim 1, characterized in that, The data processing module adjusts the control command based on the deviation between the actual operating parameters and the target parameters of the servo cylinder, thereby correcting the action of the servo cylinder.

3. The system according to claim 2, characterized in that, The drive module feeds back the actual operating parameters of the servo electric cylinder to the data processing module.

4. The system according to any one of claims 1-3, characterized in that, The data processing module includes a signal generation unit, which generates a drive signal containing the target position, target speed and acceleration of the servo cylinder according to the control command. The drive module drives the servo cylinder to move according to the drive signal.

5. The system according to claim 1, characterized in that, The sensor module includes one or more of a tilt sensor, a displacement sensor, and an encoder.

6. The system according to any one of claims 1-3, characterized in that, The system also includes a ground control center module, which is connected to the data processing module.

7. The system according to any one of claims 1-3, characterized in that, The system also includes a human-computer interaction interface, which is connected to the data processing module and used to input control parameters and display data.

8. The system according to any one of claims 1-3, characterized in that, The system also includes a leakage current detection module, which is connected to the data processing module.

9. The system according to any one of claims 1-3, characterized in that, The system also includes a remote control module, which includes a remote controller and a receiver connected to each other, and the receiver is connected to the data processing module.

10. The system according to claim 1, characterized in that, The system also includes a debugging and calibration module connected to the data processing module, used to perform initial calibration and periodic verification of the sensor to ensure data acquisition accuracy.

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