综放工作面液压支架液压缸泄漏故障诊断方法

Leakage fault diagnosis method for hydraulic cylinders of hydraulic supports in fully mechanized top-coal caving faces

  • 摘要: 针对现有液压缸泄漏故障诊断方法多依赖人工特征设计,难以充分表征综放工作面液压支架多规格液压缸样本差异,以及有杆腔、无杆腔压力动态耦合困难等问题,提出了一种基于物理先验双重交叉注意力网络的综放工作面液压支架液压缸泄漏故障诊断方法。依托液压缸泄漏故障模拟实验系统,采集6种规格液压缸在正常、内部泄漏、无杆腔外部泄漏、有杆腔外部泄漏及复合泄漏5种工况下的双通道压力信号。针对原始信号样本长度差异大、长序列建模困难及不同液压缸之间分布偏移明显等问题,采用Z−Score标准化、分段切分、线性插值及短时傅里叶变换构建统一的二维时频特征表示。依据二维时频特征表示特性,设计了物理先验双重交叉注意力网络:通过双重交叉注意力模块显式建立有杆腔与无杆腔压力时频特征之间的双向交互关系,增强网络对泄漏故障引起的跨通道耦合异常的表征能力,同时结合Transformer编码器提取深层时频特征;引入交叉熵损失与物理先验引导的泄漏一致性损失,使网络兼顾故障判别能力与泄漏机理约束。实验结果表明:双重交叉注意力模块和物理先验引导的泄漏一致性损失共同作用时取得最优诊断精度;物理先验双重交叉注意力网络的准确率达91.76%,外泄故障融合准确率达96.73%,优于其他对比网络;该网络可将误判控制在物理特征相近的外泄故障类别之间,减少了正常状态、内泄与外泄之间的混淆,表现出更强的泄漏故障识别能力,且提取的特征具有更好的类内紧凑性和类间分离性。

     

    Abstract: To address the problems that existing leakage fault diagnosis methods for hydraulic cylinders mostly rely on manually designed features, have difficulty in fully characterizing sample differences among multi-specification hydraulic cylinders of hydraulic supports in fully mechanized top-coal caving faces, and struggle to model dynamic coupling between rod-chamber and rodless-chamber pressures, this study proposed a leakage fault diagnosis method for hydraulic cylinders of hydraulic supports in fully mechanized top-coal caving faces based on a Physics-Prior Dual Cross-Attention Network (PPDCAN). Using a simulation experiment system for hydraulic-cylinder leakage faults, dual-channel pressure signals were collected from hydraulic cylinders of six specifications under five operating conditions: normal operation, internal leakage, external leakage from the rodless chamber, external leakage from the rod chamber, and compound leakage. To address the large differences in original signal sample length, the difficulty of long-sequence modeling, and obvious distribution shifts among different hydraulic cylinders, Z-Score standardization, segmentation, linear interpolation, and the Short-Time Fourier Transform were used to construct a unified two-dimensional time-frequency feature representation. According to the characteristics of the two-dimensional time-frequency representation, a PPDCAN was designed. The Dual Cross-Attention (DCA) module explicitly established bidirectional interactions between the time-frequency features of rod-chamber and rodless-chamber pressures, enhancing the network’s ability to represent cross-channel coupling anomalies caused by leakage faults. Meanwhile, a Transformer encoder was used to extract deep time-frequency features. Cross-entropy loss and Physics Prior Guided Leakage Consistency Loss (PPLCLoss) were introduced so that the network could account for both fault discrimination capability and leakage-mechanism constraints. The experimental results showed that the optimal diagnostic accuracy was obtained when the DCA module and PPLCLoss acted jointly. The accuracy of the PPDCAN reached 91.76%, and the accuracy after merging external-leakage fault classes reached 96.73%, outperforming the other baseline networks. The network confined misclassifications to external-leakage fault classes with similar physical features, reduced confusion among normal, internal-leakage, and external-leakage states, and demonstrated stronger leakage fault identification capability. The extracted features also showed better intra-class compactness and inter-class separability.

     

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