A voice terminal, a hydraulic support controller, and a hydraulic support control system

Abstract

This invention provides a voice terminal, a hydraulic support controller, and a hydraulic support control system, relating to the field of automation control equipment technology. It aims to solve the problems of complex wiring and bulky equipment in existing hydraulic support control systems and voice communication systems. The voice terminal includes a housing, and within the housing are a battery, an isolation coupling module, a locking mechanism, a speaker, and a microphone. The voice terminal is connected in series between two hydraulic support controllers via its left and right terminals. A direct-connection circuit for voice signals is provided between the terminals of the hydraulic support controllers. This invention, through product structure innovation, deeply integrates voice communication, locking functions, and the hydraulic support electrical control system at the physical level, enabling both systems to share a single cable. Simultaneously, the built-in battery hardware structure ensures continuous operation of the voice and locking functions after power failure, improving the system's reliability and safety.

Description

Technical Field

[0001] This utility model relates to the field of automated control equipment technology, and in particular to a voice terminal, a hydraulic support controller, and a hydraulic support control system. Background Technology

[0002] In the field of automated control of fully mechanized coal mining faces, the hydraulic support control system is responsible for realizing the automatic cyclic movement of the supports; the voice communication system is responsible for realizing voice interaction between personnel and interlocking control of scraper conveyors, transfer machines, and crushers.

[0003] Currently, the traditional technical solution involves placing a controller on each hydraulic support and connecting them in series via an independent cable; simultaneously, a combination loudspeaker telephone with interlocking function is placed every few supports, also connected via another independent cable. This separate deployment method results in a large number of cables on the work surface, a complex wiring structure, and a heavy workload for installation and maintenance.

[0004] Therefore, there is an urgent need for a technical solution that fundamentally optimizes the physical structure, aiming to solve the problems of complex wiring and low integration caused by the discrete deployment of existing systems. Utility Model Content

[0005] This utility model provides a voice terminal, a hydraulic support controller, and a hydraulic support control system to solve the defects of complex wiring and bulky equipment in the existing hydraulic support control system and voice communication system.

[0006] This invention provides a voice terminal for use in a hydraulic support control system. The voice terminal includes a housing, a circuit board disposed within the housing, and left and right terminals mounted on the housing. The left and right terminals are connected in series between two hydraulic support controllers and include at least a power pin, a voice signal pin, and a support electrical control signal pin. This solution, through an improved terminal connection structure, enables direct series integration of the voice terminal within the hydraulic support control system.

[0007] In another preferred embodiment of this invention, a battery is also provided inside the voice terminal housing, and the battery charging circuit is connected to the power supply pin. This battery structure provides the voice terminal with an independent power supply.

[0008] In another preferred embodiment of this invention, an isolation coupling module is further provided inside the voice terminal housing. The input and output terminals of the isolation coupling module are respectively connected to the electrical control signal pins of the left and right terminal brackets. This module structure achieves built-in integration of signal isolation and coupling functions.

[0009] In another preferred embodiment of this invention, a locking mechanism is further provided inside the voice terminal housing, and the signal output terminal of the locking mechanism is connected to the voice signal pin or an independent locking signal pin. This locking mechanism structure realizes hardware integration of the locking function.

[0010] In another preferred embodiment of this invention, a speaker and a microphone are also provided on the voice terminal housing, both of which are electrically connected to the circuit board. This acoustic component structure improves the communication function of the voice terminal.

[0011] A hydraulic support controller includes a controller housing and a first terminal and a second terminal disposed on the controller housing. The first terminal and the second terminal are connected via a direct-connect circuit. This direct-connect circuit structure ensures that the voice signal passes directly.

[0012] In another preferred embodiment of this invention, the first and second terminals on the controller housing are externally connected via a multi-core cable connector. This connector structure optimizes the external connection method of the controller.

[0013] A hydraulic support control system includes multiple hydraulic support controllers (technical solutions six or seven) and at least one voice terminal (technical solutions one to five). The voice terminal is connected in series between the terminals of two adjacent hydraulic support controllers via its left and right terminals. This connection structure achieves overall system integration.

[0014] In another preferred embodiment of this invention, the hydraulic support controller and the voice terminal are connected by a common cable, which contains independent voice signal cores and support electrical control signal cores. This cable structure supports integrated system connection.

[0015] In another preferred embodiment of this invention, the common cable further includes an independent locking signal core for transmitting the locking signal. This independent core structure ensures reliable transmission of the locking signal.

[0016] The beneficial effects of this utility model are: Firstly, by designing the voice terminal as a series structure with left and right terminals and integrating isolation coupling function inside, physical integration with the hydraulic support control system is achieved, allowing the two systems to share a single cable, fundamentally simplifying the wiring on the work surface from a physical structure perspective.

[0017] Secondly, by incorporating a battery inside the voice terminal housing, an independent power supply structure is constructed to ensure that voice communication and emergency interlocking functions continue even when the main power supply to the system is interrupted, thereby improving the safety and reliability of the system from a hardware perspective.

[0018] Thirdly, the voice terminal adopts a highly integrated modular physical structure, integrating communication, interlocking, coupling and other functional units into a single housing. This compact structure reduces potential failure points and facilitates on-site installation and maintenance. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of a hydraulic support control system provided by this utility model.

[0021] Figure 2 This is a schematic diagram of the structure of a hydraulic support controller provided by this utility model.

[0022] Figure 3 This is a schematic diagram of the structure of a hydraulic support control system provided by this utility model.

[0023] Figure 4 This is a schematic diagram of the core structure of a shared cable provided by this utility model.

[0024] Figure 5 This is a schematic diagram of the core structure of another shared cable provided by this utility model.

[0025] Figure label: 10. Voice terminal; 11. Voice terminal housing; 111. Circuit board; 12. Left terminal; 13. Right terminal; 14. Battery; 15. Isolation coupling module; 16. Locking mechanism; 17. Speaker; 18. Microphone; 20. Hydraulic support controller; 21. Controller housing; 22. First terminal; 23. Second terminal; 24. Direct connection circuit; 30. Common cable; 31. Power supply core; 32. Voice signal core; 33. Bracket electrical control signal core; 34. Locking signal core. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, 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.

[0027] The following is combined with Figure 1 Figure 5 The embodiments of this utility model are described in detail below. These embodiments are implemented based on the technical solution of this utility model, providing detailed implementation methods and specific operating procedures. However, the scope of protection of this utility model is not limited to the following embodiments.

[0028] like Figure 1 As shown, the voice terminal 10 of this embodiment includes a voice terminal housing 11, which is made of high-strength aluminum alloy material.

[0029] Optionally, the voice terminal housing 11 has an overall rectangular structure with external dimensions of 200mm × 150mm × 80mm.

[0030] Optionally, the voice terminal housing 11 adopts an explosion-proof design, which meets the explosion-proof standards for underground coal mines and has a protection level of IP67. The surface is treated with epoxy resin powder coating for corrosion protection, which can adapt to the harsh environment of dampness and dust underground.

[0031] In some embodiments, a circuit board 111 is provided in the center of the voice terminal housing 11. The circuit board is a four-layer printed circuit board (PCB) and is fixed to the bottom of the housing by four stainless steel mounting posts.

[0032] Specifically, the circuit board 111 integrates core components such as the main control processor, audio codec chip, and power management chip.

[0033] The main control processor is responsible for audio signal processing, communication protocol parsing, and system control; the audio codec chip supports multiple codec formats, ensuring voice quality while reducing bandwidth requirements.

[0034] In some embodiments, a left terminal 12 is fixedly installed on the left side wall of the voice terminal housing 11, and a right terminal 13 is fixedly installed on the right side wall.

[0035] Specifically, both the left terminal 12 and the right terminal 13 adopt intrinsically safe multi-core aviation connectors that meet coal mine safety standards. Each connector contains 8 pins, including 4 power pins (positive, negative, and ground), 2 voice signal pins (transmit and receive), 2 bracket electrical control signal pins (data+ and data-) and 1 latching signal pin.

[0036] The connector housing is made of nickel-plated brass, which has good conductivity and corrosion resistance.

[0037] In some embodiments, a battery 14 is provided in the lower right corner of the inside of the voice terminal housing 11. The battery is a lithium-ion battery pack with a rated voltage of 12V and a capacity of 5000mAh.

[0038] Specifically, battery 14 is securely fixed inside the casing by stainless steel straps, and its positive and negative terminals are connected by straps with a cross-sectional area of ​​not less than 2.5 mm². 2 The multi-strand copper core wires are connected to the power management circuit on the circuit board 111.

[0039] The power management circuit supports a maximum charging current of 2A and has multiple protection functions such as overcharge, over-discharge, overcurrent, and short circuit.

[0040] In some embodiments, the isolation coupling module 15 is installed in a dedicated area on the left side of the circuit board 111, and the module is used to achieve opto-isolation of signals.

[0041] Specifically, the input terminal of the isolation coupling module 15 is connected to the bracket control signal pin of the left terminal 12 via printed circuitry, and the output terminal is connected to the bracket control signal pin of the right terminal 13. The isolation coupling module 15 can withstand an isolation voltage of 1500Vrms, ensuring the safety of the system in the event of a fault.

[0042] In some embodiments, the locking mechanism 16 is mounted on the upper part of the front panel of the voice terminal housing 11 and includes a red emergency stop button with a diameter of 30 mm, a micro switch, and a signal generation circuit.

[0043] Specifically, the emergency stop button employs a self-locking structure, requiring rotation to reset after being pressed. The signal generation circuit uses a Schmitt trigger for signal shaping to eliminate jitter interference.

[0044] The signal output terminal of the locking mechanism 16 is connected to the voice signal pin through a shielded twisted pair cable, and the locking state is transmitted using a frequency-shift keying (FSK) signal with a frequency of 1200Hz.

[0045] In some embodiments, the speaker 17 is mounted on the top inner side of the voice terminal housing 11, and is a waterproof speaker with a diameter of 50mm, a power of 3W, and an impedance of 8Ω.

[0046] Specifically, the speaker's sound cavity radiates sound outward through the sound outlet at the top of the housing, and a waterproof and dustproof mesh is installed at the sound outlet.

[0047] In some embodiments, the microphone 18 is mounted behind the microphone hole at the lower part of the front panel of the voice terminal housing 11.

[0048] Specifically, the microphone 18 can be a micro-electro-mechanical systems (MEMS) silicon microphone with a sensitivity of -26dB and a signal-to-noise ratio greater than 60dB. A windproof sponge and a metal explosion-proof mesh are installed in front of the microphone to effectively suppress ambient noise.

[0049] Thus, this application fundamentally changes the traditional two-system independent wiring mode by designing the voice terminal as a series structure with left and right terminals, enabling it to be directly integrated into the hydraulic support control link. This allows for the simultaneous transmission of electrical control signals and voice signals using a single cable, simplifying the wiring on the work surface. Secondly, by incorporating a battery in the terminal housing and equipping it with an intelligent charging and discharging circuit, an independent power outage protection system is constructed, ensuring the continued operation of voice communication and emergency interlocking functions when the main power supply of the system is interrupted. This addresses the safety hazard of existing systems failing upon power failure from a hardware perspective. Furthermore, by adopting a highly integrated modular structure, functional units such as isolation coupling modules, interlocking mechanisms, and acoustic components are compactly integrated into an explosion-proof housing. This reduces external connection points and the probability of failure, facilitates on-site installation and maintenance, and improves the overall reliability and ease of use of the system.

[0050] like Figure 2 As shown, the hydraulic support controller 20 of this embodiment includes a controller housing 21, which is made of flame-retardant engineering plastic.

[0051] Optionally, the external dimensions of the controller housing 21 are 300mm × 200mm × 100mm.

[0052] Optionally, the controller housing 21 adopts a modular design, consisting of an upper cover, a lower shell, and a mounting plate. The mounting plate is equipped with guide rail mounting clips for easy and quick installation on a hydraulic support.

[0053] In some embodiments, a first terminal 22 and a second terminal 23 are respectively provided on the left and right sides of the controller housing 21, both of which are 24-pin intrinsically safe connectors.

[0054] Specifically, the connector pins are made of phosphor bronze with a gold-plated surface to ensure good contact performance and corrosion resistance. The connector housing has a threaded locking mechanism to prevent loosening under vibration.

[0055] In some embodiments, inside the controller housing 21, the voice signal pin of the first terminal 22 and the voice signal pin of the second terminal 23 are connected by a direct connection circuit 24.

[0056] Specifically, the direct connection circuit 24 is implemented using dedicated copper foil traces on a double-layer PCB board, with a trace width of 1.5mm, a spacing of 0.5mm, and a characteristic impedance controlled at 100Ω±10%.

[0057] Optionally, an electrostatic discharge (ESD) protection diode and an RF filter capacitor are also connected in parallel on the direct connection circuit 24 to prevent electrostatic and high-frequency interference. The direct connection circuit 24 completely bypasses the controller's main processor, forming an independent physical channel to ensure real-time transmission of voice signals.

[0058] In some embodiments, the first terminal 22 and the second terminal 23 are connected to the internal circuit of the controller via a shielded cable, with crimp connectors at both ends of the cable to ensure reliable connection.

[0059] Specifically, the main control board inside the controller is responsible for the motion control and status monitoring of the hydraulic support. The main control board also integrates communication interfaces such as a controller area network (CAN) bus controller and an Ethernet physical layer, supporting multiple communication protocols.

[0060] Thus, this application incorporates a direct voice signal circuit within the hydraulic support controller, allowing voice signals to be transmitted directly through a dedicated physical channel without passing through the main processor. This ensures extremely low latency and real-time performance of voice communication while also achieving fault isolation from the control system. Simultaneously, the use of standardized multi-core cable connectors ensures the robustness and sealing of the connection between the controller and the system, optimizes the system's scalability and maintenance convenience, and guarantees the reliability and stability of the entire system's communication from critical nodes.

[0061] like Figure 3 As shown, the hydraulic support control system consists of multiple hydraulic support controllers 20 and multiple voice terminals 10 connected in series via a common cable 30, and the power supply box 40 provides working power to the hydraulic support control system.

[0062] During actual installation at the longwall mining face, a voice terminal 10 is typically installed every 5-8 hydraulic support controllers 20. The voice terminal 10 is directly connected in series between the first terminal 22 and the second terminal 23 of two adjacent hydraulic support controllers 20 through its left terminal 12 and right terminal 13, forming a chain topology.

[0063] Thus, this application integrates the improved voice terminal and the hydraulic support controller in series on the same link, constructing a highly integrated fusion control system, and ultimately achieving the physical and logical unification of the two major functions of hydraulic support control and voice communication.

[0064] like Figure 4 As shown, the common cable 30 can be an 8-core mining flame-retardant shielded cable with an outer diameter of 15mm, and internally includes: Four wires with a cross-sectional area of ​​1.5mm 2The power supply core 31 is used to transmit intrinsically safe DC power. Among them, three are used to transmit current, and one is a grounding wire.

[0065] Two cross-sectional areas of 0.75mm² 2 The voice signal core 32 adopts a twisted pair structure and is used to transmit voice data and interlocking signals.

[0066] Two wires with a cross-sectional area of ​​1.0 mm² 2 The bracket electrical control signal core 33 adopts a twisted pair structure for differential signal transmission.

[0067] In the embodiments of this application, all wire cores are shielded by an aluminum-plastic composite tape, and the outermost layer is a neoprene rubber sheath.

[0068] like Figure 5 As shown, the common cable 30 can be a 9-core mining flame-retardant shielded cable with an outer diameter of 16mm, and internally includes: Four wires with a cross-sectional area of ​​1.5mm 2 The power supply core 31 is used to transmit intrinsically safe DC power. Among them, three are used to transmit current, and one is a grounding wire.

[0069] Two cross-sectional areas of 0.75mm² 2 The voice signal core 32 uses a twisted pair structure and is used to transmit voice data.

[0070] Two wires with a cross-sectional area of ​​1.0 mm² 2 The bracket electrical control signal core 33 adopts a twisted pair structure for differential signal transmission.

[0071] A wire with a cross-sectional area of ​​0.75 mm 2 The locking signal core 34 adopts a shielded twisted pair structure.

[0072] In the embodiments of this application, all wire cores are shielded by an aluminum-plastic composite tape, and the outermost layer is a neoprene rubber sheath.

[0073] Thus, by using a shared cable containing multiple independent cores, this application simplifies wiring while ensuring the isolated transmission of power, voice, electrical control, and interlocking signals. This avoids mutual interference between signals and ensures the absolute priority and reliable transmission of safety commands by establishing an independent channel for interlocking signals.

[0074] In actual use, the voice terminal 10 obtains its operating power from the power core 31 of the common cable 30 via the left terminal 12 or the right terminal 13. The power supply system adopts an intrinsically safe design, with a rated voltage of 18VDC and a maximum output current of 2A.

[0075] In one example, when the system is powered normally, the power supply provides power to each module through the power management circuit inside the voice terminal 10, while charging the battery 14 in a constant current-constant voltage manner.

[0076] Specifically, the charging process is divided into two stages: when the battery voltage is below 12.6V, it is charged with a constant current of 1A; when the voltage reaches 12.6V, it switches to constant voltage charging until the charging current drops below 50mA.

[0077] In another example, when the system loses power, the power management circuit automatically switches to battery 14 power supply mode within 10ms.

[0078] Specifically, in battery-powered mode, the system automatically enters a low-power state, turning off unnecessary display and indicator functions, but maintaining normal operation of voice communication and interlocking functions.

[0079] In some embodiments, the voice signal is transmitted through the voice signal core 32, using a full-duplex communication method.

[0080] Specifically, when the voice signal reaches the hydraulic support controller 20, it is directly transmitted to the next cable segment through its internal direct connection circuit 24, with a signal delay of less than 5ms, ensuring the real-time performance of voice communication.

[0081] Optionally, the isolation coupling module 15 adopts magnetic isolation technology and realizes the signal transmission of the electrical control signal cores 33 on the left and right sides of the bracket through transformer coupling.

[0082] Specifically, the isolation coupling module 15 has a transmission rate of up to 1 Mbps and supports communication protocols such as CAN bus and recommended standard 485 (RS485).

[0083] Optionally, the isolation coupling module 15 has an internal isolation barrier that can withstand a power frequency withstand voltage of 1500Vrms, ensuring the safety of personnel and equipment in the event of an electrical fault.

[0084] In some embodiments, in the common cable 30 Figure 5 When the ground cable is shown, the locking signal generated by the locking mechanism 16 is transmitted through the locking signal core 34, and can be a direct current (DC) 24V level signal.

[0085] Specifically, when the emergency stop button is pressed, the voltage on the interlock signal core drops from 24V to 0V. After this state change is detected by the system, the interlock operation of the three machines (such as scraper conveyor, transfer machine, and crusher) is immediately executed.

[0086] In practical applications, the system also supports voice broadcasting. It can simultaneously send voice commands to all subordinate voice terminals 10, enabling unified command across the work area.

[0087] Specifically, each voice terminal 10 has a unique address code and supports multiple communication modes such as single call, group call, and all call.

[0088] Optionally, the hydraulic support control system also has a self-diagnostic function, which can monitor important parameters such as cable connection status, battery power, and equipment temperature in real time, and promptly detect and report faults.

[0089] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this 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 of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A voice terminal, characterized in that, The voice terminal is used in the hydraulic support control system, and the voice terminal includes: Voice terminal housing (11); Circuit board (111) disposed inside the housing (11) of the voice terminal. The left terminal (12) and right terminal (13) installed on the voice terminal housing (11) are used to be connected in series between the two hydraulic support controllers (20); The left terminal (12) and the right terminal (13) include at least a power supply pin, a voice signal pin, and a bracket electrical control signal pin.

2. The voice terminal according to claim 1, characterized in that, The voice terminal housing (11) is also equipped with a battery (14), and the charging circuit of the battery (14) is connected to the power supply pin.

3. The voice terminal according to claim 1, characterized in that, The voice terminal housing (11) is also provided with an isolation coupling module (15), the input end and output end of the isolation coupling module (15) are respectively connected to the bracket electrical control signal pins of the left terminal (12) and the right terminal (13).

4. The voice terminal according to claim 1, characterized in that, The voice terminal housing (11) is also provided with a locking mechanism (16), and the signal output terminal of the locking mechanism (16) is connected to the voice signal pin or an independent locking signal pin.

5. The voice terminal according to claim 1, characterized in that, The voice terminal housing (11) is also provided with a speaker (17) and a pickup (18), both of which are electrically connected to the circuit board (111).

6. A hydraulic support controller for use in conjunction with the voice terminal of claim 1, characterized in that, include: Controller housing (21); The first terminal (22) and the second terminal (23) are disposed on the controller housing (21); The voice signal pins of the first terminal (22) and the second terminal (23) are connected by a direct connection circuit (24).

7. The hydraulic support controller according to claim 6, characterized in that, The first terminal (22) and the second terminal (23) are externally connected through a multi-core cable connector.

8. A hydraulic support control system, characterized in that, include: Multiple hydraulic support controllers (20) as described in claim 6 or 7; At least one voice terminal (10) as described in any one of claims 1 to 5; The voice terminal (10) is connected in series between the terminals of two adjacent hydraulic support controllers (20) via its left terminal (12) and right terminal (13).

9. The system according to claim 8, characterized in that, The hydraulic support controller (20) and the voice terminal (10) are connected by a common cable (30), which contains independent power supply cores (31), voice signal cores (32) and support electrical control signal cores (33).

10. The system according to claim 9, characterized in that, The common cable (30) also includes an independent locking signal core (34) for transmitting locking signals.

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