具有故障诊断功能的液压支架电液控制器通信系统

宋单阳; 宋建成; 陶心雅; 杨金衡; 卢春贵

doi:10.13272/j.issn.1671-251x.2021120106

具有故障诊断功能的液压支架电液控制器通信系统

doi: 10.13272/j.issn.1671-251x.2021120106

宋单阳^{1, 2,},
宋建成^{1, 2},
陶心雅³,
杨金衡^{1, 2},
卢春贵^{1, 2}

1.
太原理工大学矿用智能电器技术国家地方联合工程实验室, 山西太原　030024
2.
太原理工大学煤矿电气设备与智能控制山西省重点实验室, 山西太原　030024
3.
太原科技大学电子信息工程学院, 山西太原　030024

基金项目: 山西省重点研发计划项目（202003D111008）。

详细信息

作者简介:
宋单阳（1992-），男，山西太原人，博士研究生，主要研究方向为矿用智能电器技术，E-mail：136862475@qq.com

中图分类号: TD355
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- 被引次数: 0
出版历程
- 收稿日期: 2021-12-31
- 修回日期: 2022-04-26
- 网络出版日期: 2022-03-15

Communication system of hydraulic support electro-hydraulic controller with fault diagnosis function

SONG Danyang^{1, 2
,},
SONG Jiancheng^{1, 2},
TAO Xinya³,
YANG Jinheng^{1, 2},
LU Chungui^{1, 2}

1.
National and Provincial Joint Engineering Laboratory of Mining Intelligent Electrical Apparatus Technology, Taiyuan University of Technology, Taiyuan 030024, China
2.
Shanxi Key Laboratory of Mining Electrical Equipment and Intelligent Control, Taiyuan University of Technology, Taiyuan 030024, China
3.
School of Electronic Information Engineering, Taiyuan University of Science and Technology, Taiyuan 030024, China

摘要

摘要: 综采工作面通信节点数量多、通信距离长、电磁环境复杂。针对现有液压支架电液控制器通信系统普遍缺乏故障诊断功能的问题，以ZDYZ−JK型液压支架电液控制器为研究对象，设计了一套具有故障诊断和故障定位功能的液压支架电液控制器通信系统。该系统具有双路通信网络，其中一路采用总线结构同时连接主控制器和所有间架控制器，另一路则采用串联结构，仅连接相邻2台间架控制器。主控制器与间架控制器间的通信采用总线方式，手动模式下的间架控制器间邻架通信及控制则采用串联方式，二者互不干扰。间架控制器在接收到主控制器的通信信号后，会实时进行故障诊断并记录故障情况，同时会周期性向相邻支架上的间架控制器发送诊断信息，使得存在总线通信故障的间架控制器的诊断结果能够通过相邻支架上的间架控制器反馈给主控制器，从而可以在间架控制器发送报文功能故障或出错时及时对错误进行上报，上报内容包含控制器编号信息，以实现故障定位。试验结果表明：① 系统在121个通信节点、最大通信距离约为1 040 m时工作良好，且节点数量可继续增加，最高可达255个，该指标满足200个节点、1 000 m通信距离的设计要求。② 可对由于工作面电磁干扰、电液控制器物理损坏、电液控制器软件错误等原因造成的多种通信故障进行诊断和精确定位。
- 液压支架电液控制器 /
- 通信系统 /
- 故障诊断 /
- 故障定位 /
- 双路通信
Abstract: There are many communication nodes, long communication distance and complex electromagnetic environment in fully mechanized working face. The existing communication system of hydraulic support electro-hydraulic controller generally lacks fault diagnosis function. In order to solve this problem, a set of communication system of hydraulic support electro-hydraulic controller with fault diagnosis and fault location function is designed by taking the ZDYZ−JK type hydraulic support electro-hydraulic controller as the research object. The system has a two-way communication network. One way adopts a bus structure to connect the main controller and all the support controllers at the same time. The other way adopts a serial structure to only connect two adjacent support controllers. The communication between the main controller and the support controller adopts a bus mode. And the communication and control between adjacent support of the support controllers under the manual mode adopts a serial mode. Therefore, the two modes do not interfere with each other. After receiving the communication signal of the main controller, the support controllers can perform fault diagnosis and record fault conditions in real time. At the same time, the support controllers can periodically send diagnosis information to the support controllers on adjacent supports. Therefore, the diagnosis result of the support controller with bus communication fault can be fed back to the main controller through the support controllers on the adjacent supports. Therefore, when the function of sending a message by the support controller fails or an error occurs, the error can be reported in time. And the report content includes the controller number information to realize the fault location. The experiment results show the following two points. ① The system works well with 121 communication nodes and the maximum communication distance of 1 040 m. And the number of nodes can be increased to 255, which meets the design requirements of 200 nodes and 1 000 m communication distance. ② The system can diagnose and accurately locate various communication faults caused by electromagnetic interference of working face, physical damage of electro-hydraulic controller, software error of electro-hydraulic controller and so on.
- electro-hydraulic controller of hydraulic support /
- communication system /
- fault diagnosis /
- fault location /
- two-way communication

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图 1 通信系统网络结构

Figure 1. Communication system network structure

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图 2 CAN通信电路原理

Figure 2. Principle of CAN communication circuit

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图 3 RS485通信电路原理

Figure 3. Principle of RS485 communication circuit

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图 4 故障诊断流程

Figure 4. Flow of fault diagnosis

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图 5 带宽消耗率

Figure 5. Bandwidth consumption rate

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图 6 通信系统故障诊断功能试验平台

Figure 6. Test platform for fault diagnosis function of communication system

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表 1 主控制器发送命令报文有效内容

Table 1. Command sent message effective content of main controller

功能	支架号	命令功能码	数据
参数修改	被控支架号	7EH	数据量+数据
参数上报	被控支架号	03H	—
远程控制	被控支架号	55H	动作功能码

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表 2 间架控制器应答报文有效内容

Table 2. Response message effective content of support controller

功能	支架号	命令功能码	数据	诊断寄存器内容
参数修改	本架和邻架均发送本架支架号	7EH	—	本架发送自诊断寄存器，邻架发送协处理寄存器
参数上报		03H	数据量+数据
远程控制		55H	动作功能码

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表 3 寄存器置位规则

Table 3. Register setting rules

执行情况	自诊断寄存器	协处理寄存器
未接收到通信	初始值00H	初始值00H
接收到通信	—	01H
不能识别命令内容	01H	—
成功识别命令内容	02H	—
执行命令完毕	03H	—
应答内容发送完毕	00H	00H

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表 4 故障判断规则

Table 4. Fault judgment rules

自诊断寄存器− 协处理寄存器内容	故障诊断结果
未收到−未收到	接收命令故障
未收到−01H	通信应答故障
01H−01H	命令内容错误
02H−01H	命令执行失败
03H−01H	命令执行成功
03H−未收到	其他通信故障

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表 5 故障详情

Table 5. Fault details

故障编号	设置内容	故障类型
①	通过修改10号间架控制器软件，使其不对报文进行完整接收	典型干扰故障
②	通过修改软件，使主控制器下发错误命令功能码	典型干扰故障
③	通过修改20号间架控制器软件，跳过命令执行阶段，使命令不能被正确执行	典型软件故障
④	通过修改30号间架控制器软件，跳过应答阶段，使间架控制器不能正确应答
⑤	通过修改主控制器软件使其不进行实际的报文发送（但主控制器认为发送了报文，并会等待应答）
⑥	通过断开40号间架控制器TXD引脚使其不能发送报文	典型硬件故障
⑦	通过断开50号间架控制器RXD引脚使其不能接收报文	典型硬件故障

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表 6 故障诊断试验结果

Table 6. Fault diagnosis test results

故障编号	故障定位结果	故障诊断结果
①	10号	接收故障
②	1−120号	下发命令有误
③	20号	参数修改失败
④	30号	应答故障
⑤	1−120号	接收故障
⑥	40号	离线
⑦	50号	离线

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