A three machine digital twin and collaborative modeling method for fully mechanized working face
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摘要: 针对现有煤矿设备数字孪生建模方法主要侧重对单一设备进行建模，缺少三机耦合协同关系分析的问题，提出了综采工作面三机数字孪生及协同建模方法。采用智能体建模方法构建包含感知单元、控制单元和执行单元的采煤机、液压支架、刮板输送机智能体模型，依据三维建模流程构建对应的可视化模型，以智能体模型驱动三维模型运动，二者结合构成三机数字孪生模型；采用离散事件建模方法构建涵盖三机数字孪生模型交互过程的协同工艺模型，按照时序梳理三机开采工艺，形成三机协同工艺时序表。数字孪生模型用于描述综采三机的状态与行为，进行个体层面的仿真计算；协同工艺模型用于表征数字孪生模型之间的时序动作转换，实现对三机协同过程整体的推演。采煤机数字孪生模型的摇臂升降仿真实验结果表明，与真实设备测量数据对比，模型误差小，摇臂倾角平均误差为2.3°；液压支架数字孪生模型的连续升柱动作仿真实验结果表明，模型与真实设备的一致性好，与真实设备测量数据对比，角度平均误差为0.14°，行程平均误差为6.3 mm；结合煤矿实际生产日志对构建的三机协同模型进行虚实仿真实验，结果表明，所构建的综采工作面三机数字孪生模型与真实设备实现了相互映射，仿真结果与真实记录接近，三机协同模型可以较为准确地反映协同开采过程。综采工作面三机数字孪生及协同建模方法为综采设备及其协同关系的数字孪生建模提供了新思路。Abstract: The existing coal mine equipment digital twin modeling method mainly focuses on single equipment modeling. It lacks three machine coupling collaborative relationship analysis. In order to solve the above problems, the paper puts forward three machine digital twin and collaborative modeling method for fully mechanized working face. By adopting an intelligent modeling method, the method constructs agent-based models of a coal mining machine, a hydraulic support and a scraper conveyor which comprise a sensing unit, a control unit and an execution unit. The method constructs corresponding visual models according to a three-dimensional modeling process. The method drives the three-dimensional models to move by the intelligent models. The combination of the two forms a digital twin model of three machines. A discrete event modeling method is used to construct a collaborative process model covering the interaction process of the three machine digital twin model. The three machine mining process is sorted out according to the time sequence to form a three machine collaborative process time sequence table. The digital twin model is used to describe the state and behavior of the three machines in fully mechanized mining and to simulate the calculation at the individual level. The collaborative process model is used to represent the sequential action transformation between digital twin models and realize the deduction of the whole three machine collaborative process. The simulation of rocker lifting and lowering for the digital twin model of the shearer is carried out. The simulation results show that compared with the measured data of real equipment, the model error is small, an average error of rocker arm dip angle is 2.3°. The simulation of continuous column lifting action for the digital twin model of hydraulic support is carried out. The simulation results show good consistency between the model and real equipment. Compared with the measured data of the real equipment, the average angle error is 0.14° and the average stroke error is 6.3 mm. Combined with the actual production log of the coal mine, the virtual and real simulation experiment of the three machine collaborative model is carried out. The results show that the three machine digital twin model of the fully mechanized working face and real equipment realize mutual mapping. The simulation results are close to the real records. The three machine collaborative model can accurately reflect the collaborative mining process. The method of three machine digital twin and collaborative modeling for fully mechanized working face provides a new idea for the digital twin modeling of fully mechanized coal mining equipment and its collaborative relationship.
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图 1 数字孪生模型、智能体模型与三维模型的关系
Figure 1. Relation among digital twin model, agent model and 3D model
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图 5 采煤机左侧摇臂倾角数字孪生数据与真实数据对比曲线
Figure 5. Comparison curves between digital twin data and real data of dip angle of shearer left rocker arm
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图 7 真实液压支架与三维模型对比
Figure 7. Comparison of real equipment and 3D model of hydraulic support
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图 8 液压支架姿态各变量连续变化曲线
Figure 8. Continuous change curves of various variables of hydraulic support attitude
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图 9 真实刮板输送机与三维模型对比
Figure 9. Comparison of real equipment and 3D model of scraper conveyor
表 1 采煤机关键感知数据项
Table 1 Key perception data items of shearer
数据类型及传感器 关键感知数据项 结构尺寸 滚筒：直径、截深
摇臂：长度、旋转锚点
机身：长度、宽度、厚度倾角传感器 左右摇臂升降角度 行程传感器 左右滚筒采高卧底 测速传感器 采煤机行进速度 编码器/红外发射器 采煤机位置 
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表 2 液压支架运动仿真结果
Table 2 Hydraulic support motion simulation reaults
项目 后连杆
角度/（°）前连杆
角度/（°）立柱杆
角度/（°）平衡杆
角度/（°）掩护梁
角度/（°）顶梁
角度/（°）立柱
长度/ mm平衡杆
长度/ mm支护
高度/mm初始值 100.00 100.00 80.00 20.00 20.00 0 3000.00 1000.00 3800.00 最终值 107.17 122.89 77.62 32.50 40.85 0 3163.70 1137.40 3800.00 测量值 107.02 123.03 77.51 32.21 40.75 0.05 3158.59 1130.21 3793.39 误差 0.15 0.14 0.11 0.29 0.10 0.05 5.11 7.19 6.61
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表 3 部分三机协同工艺时序表数据
Table 3 Partial three machine collaborative process schedule data
事件名称 动作执行
对象指令持续
时间/s动作
指令采煤机开始
位置/架采煤机结束
位置/架割底煤 采煤机 5 牵启 170 170 3 左降 170 170 4 右牵 170 168 4 加速 168 150 机尾顺序移架 175号支架 3 降柱 165 164 4 移架 164 163 4 升柱 163 162
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