CN-122018590-A - Air bag quick-charging and quick-discharging control system for quick replacement of conveyer belt carrier roller under mine

CN122018590ACN 122018590 ACN122018590 ACN 122018590ACN-122018590-A

Abstract

The application discloses an airbag quick-charging and quick-discharging control system for quick replacement of a carrier roller of a conveyer belt under a mine, which constructs a self-adaptive parameter adjustment system based on working condition sensing and stage identification through the cooperative operation of a multidimensional compensation parameter library unit and a segmentation parameter generation unit. The system overcomes the defects of fixed parameters, poor environmental adaptability and single control strategy in the traditional pulse width modulation control, and realizes the transition from fixed parameters to multi-factor dynamic compensation and the crossing from uniform-speed inflation to segmented optimization control. The system can automatically adjust the control strategy according to load change, environmental fluctuation and equipment aging degree, improves the inflation efficiency and pressure control precision, reduces the mechanical abrasion and maintenance frequency of the electromagnetic valve, prolongs the service life of key execution components, and provides stable and reliable control guarantee for carrier roller replacement operation under complex underground working conditions.

Inventors

YANG CHUANJIU
LI LEI
FENG CONG
HAN FENG
WANG XIUCHUN

Assignees

山东黑豹电气科技有限公司

Dates

Publication Date: 20260512
Application Date: 20260211

Claims (10)

1. An airbag quick-charging and quick-discharging control system for quickly replacing a carrier roller of a conveyer belt under a mine is characterized by comprising the following components; the load self-adaptive recognition module is provided with a sensor group, the initial pressure change rate of the air bag, the initial sagging amount of the conveyor belt and the action current of the charging valve are respectively collected, the load coefficient is calculated through multi-source data fusion, the load working condition is divided, and the output end of the load self-adaptive recognition module is connected with the self-adaptive parameter adjustment module; the self-adaptive parameter adjusting module pre-stores basic control parameters matched with different load states, invokes corresponding parameters according to the load coefficients, performs self-adaptive correction by combining the environment temperature, the air source pressure and the accumulated use times of the air bags, identifies the current inflation stage according to the ratio relation between the real-time pressure value and the target pressure threshold value, and outputs the control parameters in stages, and the output end of the self-adaptive parameter adjusting module is connected with the intelligent segmented inflation and deflation control module; The intelligent sectional inflation and deflation control module executes sectional inflation control according to the received control parameters, prejudges a stop time point according to the pressure change trend in the accurate control stage, outputs a stop instruction in advance, triggers the opening of the deflation valve after the inflation valve is closed through delay protection, and adjusts the opening of the deflation valve in a sectional manner according to the real-time pressure value, and the output end of the intelligent sectional inflation and deflation control module is connected with the dynamic pressure compensation module; The dynamic pressure compensation module continuously monitors the pressure change of the air bag and predicts the pressure trend in the pressure maintaining stage, and when the predicted pressure value deviates from the target interval, an air supplementing instruction is sent to the intelligent segmented air charging and discharging control module, and the dynamic compensation quantity is calculated by integrating the factors of the air bag leakage rate, the temperature drift, the air source fluctuation and the load change, and the output end of the dynamic compensation quantity is connected with the state monitoring and optimizing module; The state monitoring and optimizing module records operation process data and builds a performance evaluation model to generate comprehensive scores, when the scores are lower than historical optimal values, basic control parameters are corrected and fed back to the self-adaptive parameter adjusting module, the health state of the equipment is judged by monitoring valve response characteristics, pressure maintaining attenuation characteristics and sensor drift characteristics, early warning signals are output, and the output ends of the self-adaptive parameter adjusting module, the intelligent segmented inflation and deflation control module and the dynamic pressure compensation module are respectively connected with the load self-adaptive identification module, the self-adaptive parameter adjusting module, the intelligent segmented inflation and deflation control module and the dynamic pressure compensation module.
2. The airbag quick-charging and quick-discharging control system for quick replacement of a conveyer belt idler under a mine of claim 1, wherein the load self-adaptive identification module comprises a multi-source data acquisition unit and a load characteristic calculation unit; The multi-source data acquisition unit acquires multi-source data through a sensor group, wherein the sensor group comprises a pressure sensor, a displacement sensor and a current sensor, the pressure sensor is used for acquiring an air bag pressure value at the initial stage of inflation, the displacement sensor is used for measuring the vertical sagging distance of a conveying belt, the current sensor is used for acquiring a current peak value at the moment of opening an inflation valve, and the multi-source data comprises the air bag pressure value, the vertical sagging distance and the current peak value; The load characteristic calculation unit carries out differential operation on the received pressure value to obtain a pressure change rate, carries out ratio operation on the pressure change rate, the sagging distance and the current peak value and the respective pre-stored maximum calibration value to complete normalization processing, multiplies the three normalized values by corresponding weight coefficients respectively, accumulates and sums the three normalized values to obtain a load coefficient, divides the load state into light load, medium load and heavy load by comparing the load coefficient with the magnitude relation of two preset demarcation thresholds, and outputs the load state to the self-adaptive parameter adjustment module.
3. The airbag quick-charging and quick-discharging control system for quick replacement of a conveyer belt idler under a mine of claim 2, wherein the self-adaptive parameter adjustment module comprises a multidimensional compensation parameter library unit and a segmentation parameter generation unit; the multidimensional compensation parameter library unit stores basic pulse width modulation periods, basic initial duty ratios and basic target pressure thresholds corresponding to light load, medium load and heavy load, acquires an ambient temperature value to calculate a temperature compensation quantity, acquires an air source pressure value to calculate a pressure compensation coefficient, acquires the accumulated use times of the air bags to calculate an aging compensation quantity, and outputs the basic control parameters and three types of compensation quantities to the segmentation parameter generation unit after superposition correction; The subsection parameter generating unit receives the corrected control parameter and acquires the current pressure value of the air bag in real time, calculates the ratio of the current pressure value to the target pressure threshold value, judges the rapid pressure establishment section and outputs a large duty cycle and a short pulse width modulation period when the ratio is smaller than the zero point eight, judges the smooth transition section and dynamically adjusts the duty cycle according to the pressure rising rate when the ratio is between the zero point eight and the zero point nine five, judges the accurate control section and outputs a small duty cycle and a long pulse width modulation period when the ratio is larger than the zero point nine five, and outputs the corresponding parameter to the intelligent subsection inflation/deflation control module.
4. The airbag quick-charging and quick-discharging control system for quick replacement of a conveyer belt idler under a mine of claim 3, wherein the multidimensional compensation parameter library unit comprises a working condition characteristic fusion subunit and a predictive parameter generation subunit; The working condition characteristic fusion subunit is provided with a four-dimensional coupling relation model, the four-dimensional coupling relation model carries out data coupling on a load coefficient, an ambient temperature, an air source pressure and the use times of the air bag, the four-dimensional coupling relation model stores interaction influence weights of all working condition factors obtained through historical operation data training, and the working condition characteristic fusion subunit inputs the received load coefficient, a real-time temperature value, a real-time pressure value and the use times into the four-dimensional coupling relation model to calculate to obtain a working condition complexity coefficient and a predicted inflation resistance curve and transmits the working condition complexity coefficient and the predicted inflation resistance curve to the predictive parameter generation subunit; The predictive parameter generation subunit is used for reversely deducing an optimal control track according to the working condition complexity coefficient and the pre-estimated inflation resistance curve, calculating to obtain an optimal combination of an initial duty ratio and a pulse width modulation period by solving a multi-objective optimization equation of the inflation time and the pressure overshoot, and pre-planning a switching moment and a parameter change gradient according to the slope change characteristic of the pre-estimated inflation resistance curve, wherein the switching moment comprises a rapid pressure building section, a stable transition section and an accurate control section, and transmitting a dynamic parameter sequence containing time sequence information to the segmentation parameter generation unit.
5. The airbag quick-charging and quick-discharging control system for quick replacement of a conveyer belt idler under a mine of claim 4, wherein the subsection parameter generating unit comprises an inflating stage identifying subunit and a dynamic parameter adjusting subunit; the device comprises an inflation stage identification subunit, a self-adaptive duty cycle correction and pressure overshoot suppression unit, a safety switching control unit, a pipeline inertia and air bag elastic deformation based overshoot prediction model, a pipeline inertia and air bag elastic deformation based overshoot prediction unit, a high duty cycle short period driving inflation valve and a high duty cycle short period driving inflation valve to achieve rapid pressure establishment when a pressure deviation result is in a high pressure difference interval, and a self-adaptive duty cycle correction and pressure overshoot suppression unit; The safety switching control unit starts protection delay to ensure that residual pressure is fully released when valve position feedback results are in a closed confirmation state, adopts a fully-opened air release valve to realize quick pressure release when pressure monitoring results are in a high-pressure zone, adopts half-open control to inhibit pressure release impact when the pressure monitoring results are in a medium-pressure zone, adopts micro-open control to slowly release air when the pressure monitoring results are in a low-pressure zone, and transmits whole-process pressure time sequence data to the dynamic pressure compensation module.
6. The airbag quick-charging and quick-discharging control system for quick replacement of a conveyer belt idler under a mine of claim 5, wherein the intelligent segmented charging and discharging control module comprises a predictive charging execution unit and a safety switching control unit; The predictive inflation execution unit is used for driving the inflation valve to periodically act according to pulse width modulation parameters, realizing quick establishment of pressure by adopting a large duty cycle and a short period in a quick pressure establishment stage, dynamically correcting the duty cycle according to the deviation of the pressure rising rate and the target rate in a steady transition stage, constructing an overshoot prediction model based on the pressure change rate and the system response delay in a precise control stage, calculating the continuous pressure rise caused by the inertia of a pipeline and the elasticity of an air bag after stopping inflation, and outputting an inflation stopping instruction in advance when the predicted total pressure reaches a target threshold value; The safety switching control unit is used for immediately switching off the inflation valve and starting delay time after receiving the inflation stopping instruction, confirming that the valve is completely closed according to valve position sensor feedback, opening the deflation valve after guaranteeing that the residual pressure of the pipeline is released through preset protection delay, adjusting the opening of the deflation valve according to real-time air bag pressure in a sectionalized mode, rapidly releasing pressure in a full-open mode in a high-pressure section, suppressing impact in a half-open mode in a medium-pressure section, slightly opening and slowly exhausting in a low-pressure section, and simultaneously transmitting time sequence data of the whole process pressure to the dynamic pressure compensation module.
7. The airbag quick-inflation and quick-release control system for quick replacement of a carrier roller of an underground conveyor belt of claim 6, wherein the predictive inflation execution unit comprises a segmented inflation control unit and a pressure overshoot pre-judging unit; The section inflation regulation and control unit establishes an air bag rigidity online identification model based on the gas-solid coupling characteristic, executes modal self-adaptive control according to the pressure deviation and deformation displacement coupling result, adopts a large duty ratio and short period drive and compensates air source flow pulsation in a high pressure difference interval, corrects the duty ratio to inhibit overshoot according to the viscoelastic constitutive relation in a transition interval, and transmits data to the pressure overshoot pre-judging unit; The pressure overshoot pre-judging unit establishes a hysteresis loop prediction model based on stress relaxation and creep coupling, establishes a multi-scale viscoelasticity constitutive relation considering residual stress field evolution, calculates stress relaxation continuous rising amount caused by molecular chain segment rearrangement after stopping inflation, and generates an inflation stopping instruction in advance and transmits the instruction to the safety switching control unit when the predicted total pressure reaches a target threshold value.
8. The airbag quick-charging and quick-discharging control system for quick replacement of a conveyer belt idler under a mine of claim 7, wherein the safety switching control unit comprises a charging and discharging interlocking unit and a gradient pressure releasing unit; The inflation and deflation interlocking unit is used for receiving the inflation stopping instruction, then closing the inflation valve, calculating stress relaxation rate in real time based on valve position feedback and the evolution data of the residual stress field of the air bag, judging a relaxation critical point, generating an deflation valve opening instruction when the valve position is completely closed and the residual stress is relaxed to a safety threshold value, and transmitting the deflation valve opening instruction to the gradient pressure release unit; and the gradient pressure release unit is used for constructing a pressure rebound prediction model based on gas-solid coupling rebound characteristics after receiving an air release valve opening instruction, integrating the viscoelasticity recovery of the air bag and the inertia of pipeline fluid, adjusting the opening of the air release valve according to the real-time pressure and rebound kinetic energy prediction result, rapidly releasing pressure in a high-pressure area, inhibiting rebound impact by changing the opening of a medium-pressure area, slowly exhausting air in a low-pressure area with micro-opening degree, and transmitting pressure time sequence data to the dynamic pressure compensation module.
9. The airbag quick-charging and quick-discharging control system for quick replacement of a conveyer belt idler under a mine of claim 8, wherein the dynamic pressure compensation module comprises a multiparameter coupling monitoring unit and a predictive air-supplementing regulating unit; The self-adaptive inflation track tracking unit drives an inflation valve according to pulse width modulation parameters, establishes a pressure deviation tracking model, identifies resistance mutation and corrects a duty ratio through pressure increment of adjacent sampling points, establishes a pressure overshoot prediction equation comprising valve delay, pipeline inertia and air bag elasticity in an accurate control section, solves to obtain steady-state pressure and sends a stop instruction in advance; The zero dead zone switching control unit receives the instruction and then closes the inflation valve, and the dual confirmation valve core reset and the air flow interruption are realized by detecting the return of the driving current to zero and the stop of the rising of the pipeline pressure, and after delay monitoring, the deflation valve is opened, and the opening degree is dynamically adjusted according to the ratio of the pressure to the deflation rate.
10. The airbag quick-charging and quick-discharging control system for quick replacement of a conveyer belt idler under a mine of claim 9, wherein the state monitoring and optimizing module comprises a performance degradation tracking unit and a control parameter evolution unit; The performance degradation tracking unit collects pressure and valve data of the control module, analyzes response delay to identify valve aging, monitors pressure maintaining attenuation to judge air bag leakage, compares reference value to identify sensor drift, constructs equipment health portrait and synchronously pre-warns to the load self-adaptive identification module and the self-adaptive parameter adjustment module; The control parameter evolution unit builds a model according to the inflation time sequence and the pressure precision to generate a score, triggers optimizing when the score is lower than the history optimal, corrects control parameters according to the overshoot characteristic, writes the control parameters into the parameter adjustment module, and synchronously outputs compensation instructions to the dynamic pressure compensation module to realize collaborative optimizing.

Description

Air bag quick-charging and quick-discharging control system for quick replacement of conveyer belt carrier roller under mine Technical Field The application relates to the technical field of control systems, in particular to an airbag quick-charging and quick-discharging control system for quick replacement of a carrier roller of a conveyer belt under a mine. Background The mine conveying equipment is used as core equipment of a downhole coal conveying system, and the operation stability of the mine conveying equipment is directly related to the mine production efficiency. The conveyer belt carrier roller is used as a key component for supporting the conveyer belt and bearing materials, is frequently worn in long-term high-load operation, and needs to be maintained and replaced regularly. The traditional carrier roller replacing process needs to stop and disassemble the conveying belt, and has the problems of long operation period, high labor intensity, multiple potential safety hazards and the like. In recent years, a quick replacement technology based on an air bag jacking principle is widely applied, the device drives an air bag to inflate and jack a conveying belt through a control system, an operation space is formed between a belt surface and a carrier roller set, disassembly-free quick replacement of carrier rollers is realized, and maintenance efficiency is remarkably improved. However, the control system of the existing air bag lifting device has a plurality of defects in practical application. The existing scheme adopts a pulse width modulation control mode with fixed parameters, and cannot adaptively adjust an inflation strategy according to the load change of a conveying belt, so that pressure overshoot and air bag impact damage are caused by too fast inflation under a light load working condition, insufficient jacking and operation time extension are caused by too slow inflation under a heavy load working condition, meanwhile, the high-frequency switch control mode accelerates the mechanical fatigue of an electromagnetic valve, shortens the service life of the valve and increases the maintenance cost, and the pulsating air flow characteristic is easy to cause pressure fluctuation and air bag vibration, influences the operation stability and accelerates material aging. In addition, the existing system has poor adaptability to environmental temperature change and air source pressure fluctuation, needs to rely on manual experience to frequently adjust control parameters, is complex to operate and low in reliability, and is difficult to meet the automatic operation requirement under the complex working condition of a mine. Disclosure of Invention The application mainly aims to provide an airbag quick-charging and quick-discharging control system for quickly replacing a carrier roller of a conveyer belt under a mine, so as to solve the problems of the background technology. In order to achieve the above purpose, the present application provides the following technical solutions: an airbag quick-charging and quick-discharging control system for quickly replacing a carrier roller of a conveyer belt under a mine is characterized by comprising the following components; the load self-adaptive recognition module is provided with a sensor group, the initial pressure change rate of the air bag, the initial sagging amount of the conveyor belt and the action current of the charging valve are respectively collected, the load coefficient is calculated through multi-source data fusion, the load working condition is divided, and the output end of the load self-adaptive recognition module is connected with the self-adaptive parameter adjustment module; the self-adaptive parameter adjusting module pre-stores basic control parameters matched with different load states, invokes corresponding parameters according to the load coefficients, performs self-adaptive correction by combining the environment temperature, the air source pressure and the accumulated use times of the air bags, identifies the current inflation stage according to the ratio relation between the real-time pressure value and the target pressure threshold value, and outputs the control parameters in stages, and the output end of the self-adaptive parameter adjusting module is connected with the intelligent segmented inflation and deflation control module; The intelligent sectional inflation and deflation control module executes sectional inflation control according to the received control parameters, prejudges a stop time point according to the pressure change trend in the accurate control stage, outputs a stop instruction in advance, triggers the opening of the deflation valve after the inflation valve is closed through delay protection, and adjusts the opening of the deflation valve in a sectional manner according to the real-time pressure value, and the output end of the intelligent sectional inflation and deflation control module is connected with