Intelligent control system for high-water filling coal mining

Abstract

The utility model belongs to coal mining filling equipment technical field, concretely is a kind of high water filling coal mining intelligent control system. Including: A powder mixing feeding system, for stirring and mixing A powder to form A slurry;B powder mixing feeding system, for stirring and mixing B powder to form B slurry;Pipeline conveying system, the pipeline conveying system respectively A slurry in A powder mixing feeding system and B slurry in B powder mixing feeding system are conveyed to filling working face;Control system, control system is communicated with underground monitoring terminal, sensor network and execution equipment by industrial ethernet, realizes remote monitoring and operation of filling process. The utility model can improve filling efficiency, and also can improve quality.

Description

Technical Field

[0001] This utility model belongs to the technical field of coal mining filling equipment, specifically a high-water filling coal mining intelligent control system. Background Technology

[0002] High-water backfill material is a novel type of backfill material. Its solidified body contains over 95% water, exhibiting low consistency, good fluidity, and is classified as a diffuse-flowing fluid. It possesses characteristics such as rapid hardening and early strength, good fluidity of the two main slurries (A or B slurry), and adjustable initial setting time. The resulting solidified body is hydrophilic, does not shrink or diffuse in an aqueous environment, exhibits good stability and small volumetric strain, and demonstrates excellent incompressibility under triaxial stress. High-water backfill coal mining technology refers to the backfilling operation of ultra-high-water materials in the goaf, based on fully mechanized coal mining operations.

[0003] In the field of coal mine backfilling, high-water backfilling technology is widely used due to its advantages such as rapid setting and high strength. However, existing backfilling control systems have significant drawbacks.

[0004] Low level of automation: Traditional systems rely on manual operation of mixing tanks to determine the proportion of ingredients and start / stop of plunger pumps, resulting in large fluctuations in slurry quality and the inability to achieve remote monitoring downhole.

[0005] Poor equipment reliability: Key process points (such as the finished product pool outlet and plunger pump) lack explosion-proof online monitoring instruments (such as density meters and pressure transmitters), and when failures occur frequently, the machine can only be shut down for maintenance, affecting continuous production.

[0006] Data silo problem: Parameters such as water tank level and material silo level are displayed by local mechanical instruments and cannot be transmitted to the control center in real time, making it difficult to optimize the ratio and energy consumption.

[0007] High safety risks: The filling working face is in a harsh environment, but the existing system lacks hard-wired emergency stop devices and equipment status monitoring units, which can easily lead to equipment damage accidents. Summary of the Invention

[0008] To solve the above problems, this utility model provides an intelligent control system for high-water backfilling coal mining.

[0009] This utility model adopts the following technical solution: a high-water backfilling coal mining intelligent control system, comprising:

[0010] A powder mixing and feeding system is used to stir and mix powder A to form slurry A;

[0011] The B powder mixing and feeding system is used to stir and mix B powder to form B slurry;

[0012] The pipeline conveying system conveys slurry A from the A powder mixing and feeding system and slurry B from the B powder mixing and feeding system to the filling working face.

[0013] The control system communicates with downhole monitoring terminals, sensor networks, and execution equipment via industrial Ethernet to achieve remote monitoring and operation of the filling process.

[0014] In some embodiments, the powder mixing and feeding system includes:

[0015] A pool, used to store water;

[0016] The material distribution bin is used to store powder materials;

[0017] Additive pool, used for storing additives;

[0018] The unloading distributor receives water, powder and additives from the water tank, the distribution bin and the additive tank respectively and mixes them;

[0019] A mixing tank is used to mix water, powders, and additives.

[0020] In some embodiments, the B powder mixing and feeding system has the same structure as the A powder mixing and feeding system.

[0021] In some embodiments, the pipeline delivery system includes:

[0022] The finished product tank for slurry A is used to store slurry A.

[0023] The finished product tank for slurry B is used to store slurry B.

[0024] A plunger pump, which delivers slurry A finished product tank to mixer;

[0025] B plunger pump, which delivers slurry B finished product tank to mixer;

[0026] A mixing pipeline is provided to transport the A slurry and B slurry mixed by the mixer to the filling working face.

[0027] In some embodiments, the control system includes:

[0028] Ground control cabinet, with built-in PLC controller and explosion-proof industrial switch;

[0029] An underground monitoring station, equipped with an explosion-proof touchscreen and an emergency stop button;

[0030] The sensor group includes a level transmitter installed in the water tank, a radar level gauge in the distribution bin, and a density meter and pressure transmitter in the outlet pipe of the slurry A / B finished product tank.

[0031] The actuator assembly includes a variable frequency feeder for the distribution bin, an electric regulating valve for the water tank, and a variable frequency drive for the A / B plunger pump.

[0032] The PLC controller forms a hard-wired network with the sensor group, actuator group and downhole monitoring station through an industrial switch.

[0033] In some embodiments, the ground control cabinet is equipped with:

[0034] The equipment condition monitoring unit includes a vibration sensor and a temperature sensor bolted to the housing of the A / B plunger pump;

[0035] Video surveillance unit, including explosion-proof PTZ camera;

[0036] The signal lines of the vibration sensor, temperature sensor, and explosion-proof PTZ camera are laid through galvanized steel pipes to the PLC controller.

[0037] In some embodiments, the explosion-proof touchscreen surface of the underground monitoring station is integrated with:

[0038] One-button start / stop hard button, directly hard-wired to the PLC controller;

[0039] The process parameter display area displays the measured values ​​of the density meter and pressure transmitter in real time.

[0040] Compared with the prior art, the present invention has the following beneficial effects:

[0041] 1. Improved filling efficiency and quality

[0042] By directly connecting the PLC controller in the ground control cabinet to the one-button start / stop hardware, the system startup time is reduced to 10 seconds, increasing monthly production capacity.

[0043] The closed-loop control of the outlet pipeline density meter and the variable frequency feeder reduces the fluctuation of the slurry solid-liquid ratio and improves the pass rate of the filling strength.

[0044] 2. Fundamental Enhancement of Equipment Safety and Lifespan

[0045] Vibration sensors are bolted to the piston pump motor housing to provide bearing failure early warning and reduce the rate of unexpected downtime.

[0046] Sensor signals are laid through galvanized steel pipes and combined with explosion-proof pan-tilt cameras to completely eliminate the risk of sparks in underground gas environments and reduce the annual failure rate of equipment.

[0047] 3. Structural optimization of operating costs

[0048] Centralized monitoring via ground control cabinets replaces manual inspections, reducing staff per shift by 60% (from 6 to 2 people) and saving 2 million yuan in annual maintenance costs. Attached Figure Description

[0049] Figure 1 This is a layout diagram of the intelligent control system for high-water backfilling coal mining of this utility model;

[0050] Figure 2 This is a schematic diagram of the control system of this utility model;

[0051] In the diagram, 1-water tank, 2-material distribution bin, 3-additive tank, 4-discharge distributor, 5-mixing tank, 6.1-finished slurry A tank, 6.2-finished slurry B tank, 7.1-A plunger pump, 7.2-B plunger pump, 8-mixer, 9-mixing pipeline, 10-ground control cabinet, 10.1-PLC controller, 10.2-explosion-proof industrial switch, 11-downhole monitoring station, 11.1-explosion-proof touch screen, 11. 2-Emergency stop button, 12.1-Level transmitter, 12.2-Radar level gauge, 12.3-Density meter, 12.4-Pressure transmitter, 13.1-Variable frequency feeder, 13.2-Electric regulating valve, 13.3-Variable frequency drive, 14-Equipment status monitoring unit, 14.1-Vibration sensor, 14.2-Temperature sensor, 15-Video monitoring unit, 15.1-Explosion-proof PTZ camera, 16-Water tank. Detailed Implementation

[0052] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions in the embodiments of this utility model will be clearly and completely described below. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0053] like Figure 1 As shown, this intelligent control system for high-water backfilling coal mining consists of four main physical units:

[0054] A Powder Mixing and Feeding System: Located on the east side of the ground workshop, it is used to prepare calcium-based powder slurry (A slurry).

[0055] B powder mixing and feeding system: symmetrically arranged with system A on the west side of the workshop, used to prepare sulfoaluminate powder slurry (B slurry).

[0056] Pipeline delivery system: includes two seamless steel pipes to deliver A / B slurry to the downhole mixer 8 respectively.

[0057] Control system: The core is the ground control cabinet 10, which communicates with the downhole monitoring station 11, sensor group and actuator group via an industrial Ethernet (model: Hirschmann RS30-FX) connected by armored optical cable.

[0058] Working process: After the operator starts the system at the ground control cabinet 10, the A / B systems simultaneously prepare slurry. The slurry is transported through pipelines to the downhole mixer 8 for fusion, and finally injected into the goaf through the mixing pipeline 9. The independent preparation of the two slurries avoids cross-contamination, and the entire process is remotely monitored via industrial Ethernet.

[0059] like Figure 1 As shown, Powder A mixing and feeding system:

[0060] An electric regulating valve 13.2 is installed at the outlet of water tank 1 and connected to the inlet of unloading distributor 4 via a DN50 stainless steel pipe.

[0061] The lower part of the cone section of the material distribution bin 2 is connected to the frequency converter feeder 13.1, which is connected to the dry material port of the unloading distributor 4 via a φ300mm chute.

[0062] The additive tank 3 outlet is connected to the additive inlet of the unloading distributor 4 via a diaphragm metering pump.

[0063] The bottom outlet of the unloading distributor 4 is connected to the inlet of the mixing tank 5 via a flange.

[0064] Work process:

[0065] The PLC controller 10.1 controls the opening of the electric regulating valve 13.2 and the speed of the frequency converter feeder 13.1 according to the preset ratio (water: powder: additive = 1: 0.8: 0.05). After the material is initially mixed in the unloading distributor 4, it enters the mixing tank 5 and is stirred at 120r / min for 10 minutes to form a homogeneous A slurry.

[0066] The premixing of the discharge distributor reduces the load on the mixing tank and improves the uniformity of the slurry.

[0067] The B powder mixing and feeding system is a mirror image of the A powder mixing and feeding system, using the same model of mixing tank 5, unloading distributor 4, and matching actuators. The water tanks 1 of both systems are connected to a water silo 16, which stores a large amount of water for use by both water tanks 1.

[0068] Work process:

[0069] Sulphoaluminate powder is independently pulped in system B with a water-to-powder ratio of 1:0.75, and the process flow is completely consistent with system A.

[0070] Modular design enables 100% interchangeability of components in the A / B system and reduces spare parts inventory costs by 30%.

[0071] Pipeline delivery system:

[0072] A outlet of mixing tank 5 → A finished product tank 6.1 → A plunger pump 7.1 → A inlet of mixer 8.

[0073] The B outlet of mixing tank 5 → slurry B finished product tank 6.2 → B plunger pump 7.2 → B inlet of mixer 8.

[0074] Mixer 8 outlet → φ150mm mixing pipe 9 (material: wear-resistant alloy steel) → filling working surface.

[0075] Work process:

[0076] The A / B slurries are mixed in a 3:1 volume ratio in mixer 8. After being pressurized by a plunger pump, the mixed slurry is transported to the well via mixing pipeline 9 at a flow rate of 5 m / s.

[0077] The dual-plunger pump features independent frequency conversion control, improving mixing ratio accuracy and avoiding the pulsation problem associated with traditional single-pump delivery.

[0078] Control system hardware architecture:

[0079] Installation inside ground control cabinet 10 (dimensions: 2000×800×600mm):

[0080] PLC controller 10.1 (Siemens S7-1500)

[0081] Explosion-proof industrial switch 10.2 (model: Moxa EDS-405A-EX).

[0082] Sensor group:

[0083] A level transmitter 12.1 (EJA110A, range 0-5m) is installed on the inner wall of water tank 1; a radar level gauge (12.2) (LR560, range 0-10m) is hoisted on the top of the material distribution bin (2); a density meter 12.3 is welded to the outlet pipe of the slurry A / B finished product tank; a pressure transmitter 12.4 is installed on the outlet pipe section of the plunger pump.

[0084] Actuator group:

[0085] The feeder in the material distribution bin 2 is equipped with a frequency converter 13.1; the pipeline of the water tank 1 is equipped with an electric regulating valve 13.2; the plunger pump motor is connected to the frequency converter 13.3.

[0086] The PLC acquires sensor data via the PROFIBUS bus, performs PID calculations, and outputs commands to the actuators. For example, when the density meter 12.3 detects an abnormal slurry density, the PLC adjusts the speed compensation ratio of the variable frequency feeder 13.1 in real time.

[0087] Equipment status monitoring unit 14 includes:

[0088] Vibration sensor 14.1 is vertically fixed to the axial measuring point on the motor housing of plunger pump 7.1 using M8 stainless steel bolts; temperature sensor 14.2 is embedded in the motor winding slot and encapsulated with high-temperature resistant epoxy resin. The signal line is laid through a φ25 galvanized steel pipe (2.5mm wall thickness) to the PLC analog input module.

[0089] Video surveillance unit 15:

[0090] An explosion-proof PTZ camera 15.1 is aimed at the feeding port 5 of the mixing tank and connected to an industrial switch 10.2 via an optical transceiver.

[0091] The vibration sensor 14.1 acquires 4-20mA signals in real time. When the detected value is greater than 7.1mm / s, the PLC automatically reduces the plunger pump frequency to 30Hz and triggers an audible and visual alarm.

[0092] Underground monitoring station:

[0093] The explosion-proof touch screen has machined openings on its surface: a one-button start / stop hard button 11.1a is embedded in the upper left corner; a process parameter display area 11.1b is set in the middle; and the emergency stop button 11.2 is independently installed on the side panel of the monitoring station and is directly connected to the normally closed contact of the PLC power module through a 2.5mm² shielded cable.

[0094] Press the hard button 11.1a → PLC outputs a 24V DC signal → Starts the following in sequence: electric regulating valve 13.2 → variable frequency feeder 13.1 → mixing tank motor → plunger pump variable frequency driver 13.3. The entire process requires no manual intervention.

[0095] Because powders and additives are a type of non-homogeneous material with significant particle size variations, coupled with the irregular feeding of materials into the silo during production, the material level in the silo fluctuates unpredictably. Therefore, the flow rate of the material changes randomly at every instant, resulting in varying weighing deviations due to lag. This makes it impossible to analyze using a purely time-delay mathematical model, representing one of the most difficult dynamic aspects to control in a physical system. Based on these characteristics of the raw materials, computer technology is applied to control the batching and metering process in real time. Using a purely time-delay mathematical model and a neural network method, the drop is estimated and calculated, enabling automatic correction. After weighing, the actual error is calculated based on the actual weighed value, determining a new drop value as the basis for controlled weighing. After the first weighing, a new drop value is calculated, which actually considers the errors of the previous two weighings. This correction is performed for each subsequent weighing; the more weighings performed, the smaller the weighing error becomes.

[0096] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A smart control system for high-water backfilling coal mining, characterized in that, include: A powder mixing and feeding system is used to stir and mix powder A to form slurry A; B powder mixing and feeding system, used to stir and mix B powder to form B slurry; The pipeline conveying system conveys slurry A from the A powder mixing and feeding system and slurry B from the B powder mixing and feeding system to the filling working face. The control system communicates with downhole monitoring terminals, sensor networks, and execution equipment via industrial Ethernet to achieve remote monitoring and operation of the filling process.

2. The intelligent control system for high-water backfilling coal mining according to claim 1, characterized in that, The A-powder mixing and feeding system includes: Pool (1), for storing water; The material distribution bin (2) is used to store powder materials; Additive pool (3) is used to store additives; The unloading distributor (4) receives water, powder and additives from the water tank (1), the distribution bin (2) and the additive tank (3) respectively and mixes them. Mixing tank (5) is used to mix water, powder and additives.

3. The intelligent control system for high-water backfilling coal mining according to claim 2, characterized in that, The B powder mixing and feeding system has the same structure as the A powder mixing and feeding system.

4. The intelligent control system for high-water backfilling coal mining according to claim 2, characterized in that, The pipeline transportation system includes: The finished product tank for slurry A (6.1) is used to store slurry A; The finished product tank for slurry B (6.2) is used to store slurry B. A plunger pump (7.1) delivers slurry A finished product tank (6.1) to mixer (8). B plunger pump (7.2), which delivers slurry B finished product tank (6.2) to mixer (8); The mixing pipeline (9) delivers the A slurry and B slurry mixed by the mixer (8) to the filling working face.

5. The intelligent control system for high-water backfilling coal mining according to claim 4, characterized in that: The control system includes: Ground control cabinet (10), with built-in PLC controller (10.1) and explosion-proof industrial switch (10.2). The underground monitoring station (11) is equipped with an explosion-proof touch screen (11.1) and an emergency stop button (11.2). The sensor group includes a level transmitter (12.1) installed in the water tank (1), a radar level gauge (12.2) in the distribution bin (2), a density meter (12.3) and a pressure transmitter (12.4) in the outlet pipe of the slurry A / B finished product tank. The actuator assembly includes a variable frequency feeder (13.1) for the distribution bin (2), an electric regulating valve (13.2) for the water tank (1), and a variable frequency drive (13.3) for the A / B plunger pump. The PLC controller (10.1) is connected to the sensor group, actuator group and downhole monitoring station (11) via an industrial switch (10.2) to form a hard-wired network.

6. The intelligent control system for high-water backfilling coal mining according to claim 5, characterized in that, The ground control cabinet (10) is equipped with: The equipment status monitoring unit (14) includes a vibration sensor (14.1) and a temperature sensor (14.2) bolted to the housing of the A / B plunger pump. The video surveillance unit (15) includes an explosion-proof PTZ camera; The vibration sensor (14.1), temperature sensor (14.2), and signal lines of the explosion-proof PTZ camera are laid through galvanized steel pipes to the PLC controller (10.1).

7. The intelligent control system for high-water backfilling coal mining according to claim 5, characterized in that, The explosion-proof touchscreen (11.1) of the downhole monitoring station (11) integrates the following: A one-button start / stop function is hard-wired directly to the PLC controller (10.1); The process parameter display area displays the measured values ​​of the density meter (12.3) and pressure transmitter (12.4) in real time.

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