基于扩张状态观测器的煤矿自动化钻机转速控制系统

Rotational speed control system of coal mine automatic drilling rig based on extended state observer

  • 摘要: 在煤矿井下自动化钻进过程中,保持钻机转速稳定并使其精确跟踪最优值是实现智能钻探的关键,也是提升钻进安全性和钻进效率的基础。针对含煤地层的不确定性导致的钻进负载多变、钻机转速难以精准跟踪与控制的问题,设计并实现了一种基于扩张状态观测器的煤矿井下自动化钻机转速控制系统。首先,基于钻机回转系统的电控液驱原理,建立其动力学模型,考虑钻机回转系统的阶跃响应特性,将其简化为一阶系统;进而采用最小二乘法辨识系统参数,得到回转系统的数学模型。随后,通过分段函数拟合输入控制信号与转速的稳态关系,建立了不同控制信号下回转系统的稳态模型,为克服系统启动时的死区效应和提升响应速度提供了理论依据。其次,设计了一种集扩张状态观测器、PI控制器和死区补偿器于一体的钻机转速控制系统。其中,扩张状态观测器将回转负载转矩视为扩张状态,并通过实时观测与前馈补偿,抑制岩层硬度变化对转速的影响。PI控制器根据转速偏差动态调节控制信号,实现高精度转速跟踪。死区补偿器基于稳态模型,根据设定转速给出控制信号的初始值,使回转系统快速脱离死区,优化系统响应。最后,开展了不同场景下回转系统闭环仿真试验与现场实钻试验。结果表明:设计的控制系统具备良好的动态性能,可在3 s内将转速稳定至设定值,满足回转系统在复杂工况下的启停控制需求;稳态误差能够控制在±3 r/min以内,有效提升了钻进过程的均匀性和系统运行的稳定性与安全性。为煤矿井下复杂条件下安全高效智能钻探提供了有力的理论与实践支撑。

     

    Abstract: Maintaining a stable rotational speed and ensuring accurate tracking of the optimal value during automated underground coal mine drilling is essential for achieving intelligent drilling, and forms the foundation for improving both drilling safety and efficiency. To address the problem of fluctuating drilling loads caused by coal-bearing stratum geological uncertainties—which makes precise control of drill rig rotational speed challenging—an automatic rotational speed control system in coal mines based on an Extended State Observer (ESO) is designed and implemented. First, a dynamic model of the electro-hydraulic rotary drive system is established based on its operating principles. Considering the step-response characteristics of the system, it is simplified to a first-order model. Then, the least squares method is adopted to identify the system parameters, and the mathematical model of the slewing system is obtained. Subsequently, the steady-state relationship between the input control signal and the rotational speed was fitted using a piecewise function, and the steady-state models of the slewing system under different control signals were established. This provides a theoretical basis for overcoming the dead-zone effect during system startup and improving the response speed. Second, A composite control scheme is designed by integrating an ESO, a PI controller, and a dead-zone compensator. The ESO treats the rotary load torque as an extended state, and mitigates the impact of rock stratum hardness variations on rotational speed through real-time observation and feedforward compensation. The PI controller dynamically adjusts the control signal based on the speed deviation to achieve high-precision speed tracking. The dead-zone compensator provides an initial control signal based on the steady-state model and the desired speed, enabling the system to quickly overcome the dead-zone effect and improve response performance. Finally, closed-loop simulation experiments and on-site actual drilling tests of the slewing system were carried out under different scenarios. The results show that the proposed control system exhibits good dynamic performance, stabilizing the rotational speed to the setpoint within 3 s and meeting the on/off control requirements of the rotary system under complex working conditions. The steady-state error is maintained within ±3 r/min, significantly enhancing the uniformity of the drilling process and the operational stability and safety of the rotary system. It provides strong theoretical and practical support for safe, efficient, and intelligent drilling under complex conditions in underground coal mines.

     

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