智能开采装备全位姿测量及虚拟仿真控制技术

Key technologies of all position and orientation monitoring and virtual simulation and control for smart mining equipment

  • 摘要: 针对深部开采复杂地质条件下的综采装备空间位姿及力学状态动态变化、随机倾斜错动难以描述和自适应控制难题,提出了基于全位姿测量及虚拟仿真控制的智能开采模式,以中煤新集口孜东矿140502工作面地质条件和7 m四柱大采高综采装备参数为基础,构建复杂条件下智能开采装备全位姿测量及虚拟仿真智能控制系统。首先,给出了智能开采“环境装备-仿真模拟-反向控制”运行体系下的智能决策过程,提出了融合视觉的装备全位姿测量、工作面装备位姿一体化描述及驱动关系建模、基于Unity3D的综采虚拟仿真控制等3项支持智能决策的关键技术。随后建立融合视觉的工作面综采装备群全位姿多参数测量系统,提出了基于设备特征点的视觉多参数测量方法,获取描述综采装备群空间全位姿的15个独立参数;给出综采装备群统一坐标描述及驱动模型,建立了特定的全局和局部坐标系、采煤机和刮板输送机位姿驱动关系模型和刮板输送机三维空间弯曲姿态模型;基于Unity3D虚拟仿真技术构建了工作面场景、装备、工艺流程等虚拟实体和关系模型,支撑井下综采装备开采过程运动仿真。开发了与全位姿测量系统通信的底层数据接口,获取装备的实际工况数据从而驱动仿真模型实现三维场景下的虚实映射。分析计算和模拟优化下一割煤循环装备协同运动及工艺过程,通过反向控制链路实现对装备虚拟模型和实际装备体的闭环控制。实验室测试表明:虚拟仿真系统实现了数据获取、模型解算、单机装备及装备群协同运动仿真,满足装备实际运行逻辑关系,具有对工作面装备运行状态实时监测和反向控制能力,系统运行流畅性满足要求,帧率>20 fps。全位姿测量系统经井下现场测试表明:图像识别检测的支架数大于5架,图像解算时间小于0.5 s,支架顶梁测量角度误差在0.4°~1.2°,满足系统数据测量需求。

     

    Abstract: Aiming at the problems of spatal position of longwall mining equipment and dynamic change of mechanical state,the difficulty of describing random tilt misalignment and adaptive control for deep mining in complex geological conditions,an smart mining model based on full position and orientation measurement and virtual simulation control was proposed. Based on the geological conditions of the 140502 working face in Kouzidong mine of China and the pa- rameters of 7 m high four legs longwall mining equipment,the full position and orientation measurement smart mining equipment and virtual simulation intelligent control system under complicated conditions were constructed. Firstly,an intelligent decision-making process under intelligent mining operation system “environment and equipment-simulation- reverse control” was given,where the key technologies supporting the above intelligent decision were proposed,inclu- ding full-position measurement with vision-enabled equipment,the vision-integrated equipment full pose measurement, and virtual simulation control of longwall mining by Unity3D. Secondly,a full-position and multi-parameter measure- ment system integrated vision for the longwall mining equipment group was established. In this system,a visual multi- parameter measurement method based on equipment feature points was proposed to obtain 15 independent parameters describing the full position and orientation of the longwall mining equipment group. A unified coordinate description and driving model of longwall mining equipment group was given,including the specific global and local coordinate system,the position driving relationship model between shearer and scraper,and the three-dimensional space bending attitude model of scraper conveyor. Based on Unity3D virtual simulation technology,the virtual entities and relationship models of working face scene,equipment,process flow,etc. were constructed to support the motion simulation of the mining process of longwall mining equipment. Also,a low-level data interface was developed to communicate with the full-position measurement system,so that the actual operating condition data of the equipment can be obtained to drive the simulation model and realize the virtual-real mapping in a three-dimensional scene. Finally,the coordinated motion and process of the equipment in next coal cutting cycle can be analyzed,calculated,simulated and optimized,and a closed-loop control of the equipment virtual and actual model was realized through the reversing control link. Laborato- ry tests of the full-posture measurement system showed that the virtual simulation system could achieve the data acqui- sition,model calculation,and coordinated motion simulation of stand-alone equipment and equipment groups,meet the actual operational logic relationship between equipments,have the capacities for the real-time monitoring and reversing control of equipment operating status in working face,and run smoothly,frame rate is faster than 20 fps. Field tests showed that the number of hydraulic supports for image recognition and detection was more than five,the image resolu- tion time was less than 0. 5 s,and the measurement angle error of the support stull was lessthan 1. 2°,which meet the requirements of data measurement.

     

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