Mechanism interference critical characterization and autonomous demodulation method of solid filling hydraulic support
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摘要:
在采充工序自驱执行过程中，能否实现机构干涉的自主解调，是固体充填液压支架能否实现智能化的基础。利用理论分析方法，以ZC5160/30/50型固体充填液压支架为例，从充填支架机构的几何及运动约束关系出发，建立了正交位姿控制指标：夯实铰点顶梁平距和夯实铰点顶梁垂距，实现了任意工况下支架后顶梁的位姿表征；分析了充填支架底卸式输送机在各工况因素作用下的运动特征，建立了正交位姿控制指标：底卸式输送机顶梁垂距和输送机顶梁平距，实现了任意工况下底卸式输送机的位姿表征；基于后顶梁和底卸式输送机的位姿控制指标进一步得出充填物料卸料过程中在煤层底板的落点位置表征指标：卸料中心距，实现了任意工况下充填物料的落点位置表征；分析了采充工序执行过程中各工序阶段机构动作与位姿调整的衔接关系和易干涉位置，基于正交位姿控制指标，利用投影法建立了任意工况下落料与典型碰撞位置的干涉临界控制方程；以夯实机构转角和夯实油缸行程表征典型工况下的干涉临界曲线，提出采用“干涉区、易干涉区、非干涉区”的三区分布特征表征干涉临界程度，并给出各干涉状态的解调路经；基于干涉临界控制方程、干涉三区分布特征和充填工序过程中机构动作与位姿调整的衔接关系，提出了干涉状态自主识别方法：利用角度传感器及行程传感器获取夯实机构的实时转角和行程，代入各易干涉位置的干涉临界方程得到处于该位置干涉临界状态的夯实机构转角或行程的理论值和干涉临界曲线，判断实际值在干涉临界曲线三区分布图上的位置即可实现干涉位置及状态的自主判别，根据干涉三区分布曲线图即可实现自主解调；基于干涉位置及干涉状态自主识别方法设计了干涉自主判别和解调算法。研究结果为充填液压支架机构位姿表征提供了新的参考指标，为机构干涉的智能避障和解调提供了基础判据，为固体智能充填的采充工序自驱执行提供了算法基础。
Abstract:Whether the self-demodulation of mechanism interference can be realized in the self-driven execution process of filling operation is the basis for the solid filling hydraulic support to achieve intelligence. Using the theoretical analysis method, taking the ZC5 160/30/50 type solid filling hydraulic support as an example, starting from the geometric and motion constraint relationship of the filling support mechanism, the orthogonal pose control index is established: the horizontal distance and vertical distance of the tamping hinge point top beam, which realizes the pose characterization of the rear top beam of the support under any working condition; The motion characteristics of the bottom-discharge conveyor of the filling support under various working condition factors were analyzed, and the orthogonal pose control index was established: the vertical distance and horizontal distance of the top beam of the bottom-discharge conveyor, which realized the pose characterization of the bottom-discharge conveyor under any working condition; Based on the pose control index of the rear top beam and the bottom-discharge conveyor, the landing position characterization index of the filling material on the coal seam floor during the discharge process is further obtained: the discharge center distance, which realizes the landing position characterization of the filling material under any working condition; the connection relationship and easy interference position of the mechanism action and pose adjustment in each stage of the filling operation process are analyzed, based on the orthogonal pose control index, the interference critical control equation of the discharge and typical collision position under any working condition is established by using the projection method; taking the tamping mechanism rotation angle and tamping cylinder stroke as the characterization of the interference critical curve under typical working conditions, it is proposed to use the three-zone distribution characteristics of “interference zone, easy interference zone, and non-interference zone” to characterize the interference critical degree, and give the demodulation path of each interference state; based on the interference critical control equation, interference three-zone distribution characteristics and the connection relationship of mechanism action and pose adjustment in the filling operation process, an interference state autonomous identification method is proposed: using angle sensor and stroke sensor to obtain the real-time rotation angle and stroke of the tamping mechanism, substituting into the interference critical equation of each easy interference position to obtain the theoretical value and interference critical curve of the tamping mechanism rotation angle or stroke in that position, judging the position of the actual value on the interference critical curve three-zone distribution diagram can realize the autonomous discrimination of interference position and state, and autonomous demodulation can be realized according to the interference three-zone distribution curve diagram; based on the interference position and interference state autonomous identification method, the interference autonomous discrimination and demodulation algorithm is designed. The research results provide new reference indicators for the pose characterization of the filling hydraulic support mechanism, provide basic criteria for the intelligent obstacle avoidance and demodulation of mechanism interference, and provide algorithm basis for the self-driven execution of the filling operation of solid intelligent filling.
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图 8 典型工况下干涉临界曲线
Figure 8. Interference critical curve under typical working conditions
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图 9 干涉临界自主判别与调控算法
Figure 9. Interference critical autonomous discrimination and regulation algorithm
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图 10 充填液压支架数值仿真试验平台
Figure 10. Numerical simulation test platform of filling hydraulic support
表 1 机构位姿控制指标及表征对象
Table 1 Position and attitude control index and characterization object of mechanism
指标 表达式 表征对象 ① 输送机顶梁平距 $ {L_{\rm{s}}} = {l_2} + {h_y} + g\sin\, \delta $ 输送机位姿 ② 输送机顶梁垂距 $ {L_{\rm{g}}} = {l_3} + {l_4} + g\cos\, \delta $ ③ 夯实铰点顶梁垂距 $ {H_{\rm{d}}} = H\cos \gamma - {L_h}\sin\, \gamma $ 后顶梁位姿 ④ 夯实铰点顶梁平距 $ {L_{\rm{d}}} = {L_h}\sec \gamma + {H_d}\tan\, \gamma $ ⑤ 卸料中心距 ${a_{\rm{z} } } = {H_{\rm{c}}} + {H_z}\tan\; \beta$ 物料落点位置 
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表 2 干涉临界典型工况参数取值
Table 2 Parameter values of interference critical typical working conditions
工况参数 h/mm β/(°) γ/(°) hy/mm 落料干涉 4500 −15、0、15 5 800 输送机底部 −15、0、15 800 输送机后侧 −15、0、15 200
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表 3 干涉自主识别与解调算法仿真试验结果
Table 3 Simulation test results of interference self-recognition and demodulation algorithm
夯实角试验值$\theta '$/(°) 夯实行程试验值
${h_{\rm{s}}}'$/mm夯实行程临界值
${h_{\rm{s}}}$/mm干涉三区分布 模拟工序
阶段识别干涉状态 卸料 输送机底部
(夯实机构伸出)输送机后侧
(夯实机构收回)27.73 800 786.64 干涉区 干涉区 干涉区 卸料前准备 卸料干涉 600 易干涉区 易干涉区 易干涉区 正常卸料 23.02 1400 1 328.95 干涉区 干涉区 易干涉区 循环夯实
(伸出)输送机底部干涉 1200 干涉区 易干涉区 干涉区 正常伸出夯实 24.47 1500 1 427.53 干涉区 干涉区 易干涉区 循环夯实
(收回)收回过程易干涉 1350 干涉区 干涉区 干涉区 输送机后侧干涉 20 2105 — 干涉区 易干涉区 非干涉区 循环夯实
(往复)正常循环夯实
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