Digital twin system architecture and key technology of following process for fully mechanized mining
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摘要: 针对综采自动化跟机工艺设计和参数调试成本高、周期长、过程繁琐的问题，提出了综采跟机工艺数字孪生系统架构，从物理设备、虚实交互、孪生数据、机理模型、仿真算法和工艺应用等层面进行分析，并对跟机工艺数据传输和存储、跟机工艺历史回放、实时跟机工艺孪生演绎、跟机工艺预演仿真、跟机工艺指令调度等关键技术进行了详细描述。提出了综采跟机工艺数字孪生系统技术路线：通过万兆光纤环网+5G通信将采煤机工艺动作数据汇集到采煤机主机，将串行支架控制器发出的支架工艺动作数据汇集到电液控主机，对工艺数据按动作时序进行收集、归类、编码，作为工艺过程回放的数据源；同时，主机将实时上报的跟机工艺数据转发给三维数字孪生系统，在三维虚拟场景中孪生演绎跟机过程；在人机交互界面完成跟机工艺参数配置后，可在三维场景中预演综采跟机工艺过程；在实时开采过程中，汇集各类传感数据，结合预演无误的跟机工艺，系统统筹下发工艺调度指令，将支架控制器从决策者转变为执行者，克服因井下空间不足导致控制器算力有限的局限性。现场应用结果表明，综采跟机工艺数字孪生系统可为综采跟机工艺设计、参数配置、仿真测试提供技术参考，使跟机工艺开发周期由14 d缩短至1 d，跟机工艺设计修改更加便捷，综采工作面跟机自动化率提高到90%以上。Abstract: The process design and parameter debugging of automatic following machine for fully mechanized mining are costly, time-consuming and cumbersome. In order to solve the above problems, the digital twin system architecture of following process for fully mechanized mining is proposed. The study analyzes the aspects of physical equipment, virtual and real interaction, twin data, mechanism model, simulation algorithm and process application. The key technologies such as the transmission and storage of the following process data, the playback of the following process history, the real-time following process twin deduction, the rehearsal simulation of following process, and the instruction scheduling of following process are described in detail. The paper puts forward the technical roadmap of the digital twin system of following process for fully mechanized machining. Through 10 Gigabit optical fiber ring network+5G communication, the shearer process action data is collected to the shearer host. The support process action data sent by the serial support controller is collected to the electrohydraulic control host. The process data is collected, classified and coded according to the action sequence as the data source for the playback of the process. At the same time, the host computer forwards the real-time reported following process data to the 3D digital twin system. The twin system deduces the following process in the 3D virtual scene. After the following process parameters are configured on the human-computer interface, the following process for fully mechanized mining can be previewed in the 3D scene. During the real-time mining process, the system will collect all kinds of sensor data and issue process scheduling instructions in combination with the rehearsal of error-free following process. The support controller is changed from a decision-maker to an executor to overcome the limitation of the limited computing power of the controller due to the lack of underground space. The field application results show that the digital twin system can provide technical reference for the process design, parameter configuration and simulation test of following process for fully mechanized mining. The system can shorten the development cycle of the following process from 14 days to 1 day, making the modification of the following process design more convenient. The system improves the following automation rate in working face to more than 90%.
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图 1 综采跟机工艺数字孪生系统架构
Figure 1. Digital twin system architecture of following process for fully mechanized mining
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图 2 综采跟机工艺数字孪生系统技术路线
Figure 2. Technical roadmap of digital twin system of following process for fully mechanized mining
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图 4 采煤机滚筒与支架护帮顶梁干涉预警
Figure 4. Early warning of interference between shearer drum and support top beam
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图 5 综采跟机工艺数字孪生系统现场应用
Figure 5. Field application of digital twin system of following process for fully mechanized mining
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