Virtual debugging method of hydraulic support group following machine process based on digital twin
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摘要:
针对物理综采工作面“三机”跟机自动化工艺参数调试周期长，费用成本高，以及工作环境搭建困难等问题，基于数字孪生技术，研究了液压支架群跟机行为工艺虚拟调试关键技术。首先基于现代建模技术构建了1∶1构综采“三机”孪生体，利用虚拟现实引擎对综采“三机”运动单元进行了虚拟重构和虚拟仿真；然后基于现代设计理论，依据“三机”协同原则实现了跟机自动化过程中的不同参数配置，建立了采煤工艺的支架行为工艺决策模型和支运装备直线度协同控制模型，并在虚拟场景中对决策模型进行预演；最后利用TCP协议建立了虚实交互通道，通过半实物仿真试验对决策模型进行了验证。结果表明：虚拟场景在执行采煤工艺时可对物理工作面场景进行精准复现，通过支架群行为决策模型可提前对液压支架工艺行为进行决策规划，通过反向控制试验可对支架控制器进行实时虚实交互，有望克服井下调试环境阻碍，对综采“三机”电液控程序的合理制定与修正提供参考价值。
Abstract:In view of the problems such as long period of automatic process parameter debugging, high cost and difficult construction of working environment, the key technology of virtual process debugging of hydraulic support group process is studied based on digital twin technology. Firstly, based on modern modeling technology, a 1∶1 twin of three fully-mechanized mining machines was constructed, and virtual reconstruction and simulation of the three mechanized mining machines were carried out by virtual reality engine. Then, based on the modern design theory and the principle of three-machine collaboration, different parameters in the automatic process of the following machine are configured, and the decision-making model of the support behavior of the coal mining process is established, and the decision-making model is rehearsed in the virtual scene. Finally, the virtual and real interaction channel is established by TCP protocol, and the decision model is verified by semi-physical simulation experiment. The results show that the virtual scene can accurately reproduce the physical working face scene in the implementation of coal mining technology, the support group behavior decision model can be used to make decision planning of the hydraulic support process behavior in advance, and the real-time virtual-real interaction of the support controller can be carried out through the reverse control experiment. It is expected to overcome the obstacles of underground commissioning environment and provide useful reference value for the reasonable formulation and revision of hydraulic control program of the third mechanized mining machine.
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图 1 液压支架群电液控虚拟调试技术框架
Figure 1. Hydraulic support group electrohydraulic control virtual debugging technology frame
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图 6 综采支运装备推进示意
Figure 6. Schematic of fully-mechanized mining support and transport equipment
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图 7 跟机行为决策预演场景
Figure 7. Follow the machine automated behavior decision rehearsal scenario
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图 8 采煤支运装备协同控制
Figure 8. Cooperative control of fully-mechanized mining support and transportation equipment
表 1 工作面设备配置
Table 1 Equipment configuration of fully-mechanized mining face
装备类型 型号 数量 端头支架 ZTZ20000/28.5/42 1 过渡支架（机头） ZF13000/27.5/42H 5 过渡支架（机尾） ZF13000/27.5/42H 4 中部支架 ZF15000/27.5/42 108 前部刮板输送机 JTAFC1050 1 后部刮板输送机 JTAFC1050 1 转载机 JBSL600 1 破碎机 JCRSH400 1 带式输送机 DSJ140/3×630 1 采煤机 Eickhoff SL-500 1 
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表 2 采煤工艺流程
Table 2 Coal mining process flow
工艺序号 执行工艺 工艺序号 执行工艺 01 (一刀开始)采煤机行走 07 采煤机前后滚筒下放 02 后滚筒后1～2支
架降移升08 采煤机来回扫地2～3次 03 执行降移升后，伸缩梁伸
且打开护帮板09 斜切进刀割三角煤（留出刮板输送机空间） 04 成组推刮板输送机
（后滚筒超过约10台支架）10 采煤机前后滚筒下放 05 成组放煤（成组推刮板
输送机后的支架）11 采煤机来回扫地2～3次 06 采煤机行至支架尾部 12 调整前后滚筒高度（准备下一刀）
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表 3 液压支架动作时间符号
Table 3 Hydraulic support action time symbol
动作 符号 动作 符号 液压支架收护帮 $ {t_1} $ 液压支架升柱 $ {t_5} $ 液压支架伸缩梁伸出 $ {t_2} $ 液压支架展护帮 $ {t_6} $ 液压支架降柱 $ {t_3} $ 液压支架成组推刮板输送机 $ {t_7} $ 液压支架拉架 $ {t_4} $ — —
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表 4 采煤机速度为$ 4\;{\mathrm{m}}/\min $支架工艺架号
Table 4 Shearer speed is 4 meters per minute support process frame number
支架工艺架号 采煤机 收护
帮板临时
支护支架降
移升成组
推刮板输送机第一轮
放煤第二轮
放煤24 30 26 17—18 — — — 25 31 27 18—19 6—13 6,8,10,12 7,9,11,13 26 32 28 19—20 — — — 27 33 29 20—21 — — — 28 34 30 21—22 — — — 29 35 31 22—23 — — — 30 36 32 23—24 — — — 31 37 33 24—25 12—19 12,14,16,18 13,15,17,19 32 38 34 25—26 — — — ... ... ... ... ... ... ... 114 120 116 107—108 — — — 115 121 117 108—109 96-103 96,98,100,102 97,99,101,103 116 122 118 109—110 — — —
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表 5 采煤机速度为$ 8\;{\mathrm{m}}/\min $支架工艺架号
Table 5 Shearer speed is 8 meters per minute support process frame number
支架工艺架号 采煤机 收护
帮板临时
支护支架降
移升成组
推刮板输送机第一轮
放煤第二轮
放煤24 30 26 16—18 — — — 25 31 27 17—19 6—13 6,8,10,12 7,9,11,13 26 32 28 18—20 — — — 27 33 29 19—21 — — — 28 34 30 20—22 — — — 29 35 31 21—23 — — — 30 36 32 22—24 — — — 31 37 33 23—25 12—19 12,14,16,18 13,15,17,19 32 38 34 24—26 — — — ... ... ... ... ... ... ... 114 120 116 106—108 — — — 115 121 117 107—109 96—103 96,98,100,102 97,99,101,103 116 122 118 109—110 — — —
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