CN110836824A - Method for identifying rock hardness based on hydraulic cylinder pressure signal and identification platform thereof - Google Patents
Method for identifying rock hardness based on hydraulic cylinder pressure signal and identification platform thereof Download PDFInfo
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Abstract
The invention relates to a method for identifying rock hardness based on a hydraulic cylinder pressure signal and an identification platform thereof, aiming at the problems that the rotation speed, the swing speed or the drilling speed of a cutting head cannot be effectively adjusted in real time according to the hardness of cut rocks in the process of cutting rock walls by a heading machine, the cutting power is often over-limit, cutting teeth can be abraded, broken, a cutter head falls off and the like, and the service life of the heading machine is greatly shortened. The invention provides a novel method for identifying the hardness of cutting rocks based on a hydraulic cylinder pressure signal of a heading machine. The method comprises the steps of researching the transmission characteristic between cutting dynamic load and hydraulic cylinder pressure signals by analyzing the change rule of cutting head load under different cutting rock characteristics, and constructing a function model between cutting hydraulic cylinder pressure and cutting rock hardness coefficient; and developing an online cutting rock hardness identification system in MATLAB.
Description
Technical Field
The invention relates to a cutting dynamic load identification simulation method of a heading machine, in particular to a method for identifying rock hardness based on a hydraulic cylinder pressure signal and an identification platform thereof.
Background
Heading machines have become the primary equipment for roadway mining and are widely used in tunnels, mining and civil engineering worldwide. Due to the complexity and instability of the surrounding rock characteristics of the roadway, the shape of the roadway is changed continuously, and the hardness of the rock is changed randomly. Especially for cutting rocks with high hardness grade and wide variation range, the load of the cutting head of the heading machine is constantly changing. However, the heading machine is huge in size and complex and harsh in operation environment, so that at present, a driver manually operates the heading machine to work, and the cutting rotating speed and the swing speed cannot be adjusted in real time according to the cutting load in the cutting process. Complicated and variable cutting loads can often cause the phenomena of power overrun of the heading machine, abrasion and breakage of cutting teeth, falling of a cutter head and the like, so that the cutter head is failed and equipment is damaged, and the service life of the heading machine is greatly shortened.
A large number of researchers have conducted a great deal of research in the relevant aspects of heading machines. Erginand Acaroglu et al establish a mathematical model of a longitudinal axis type heading machine cutting system, and obtain a three-way stress calculation formula of a heading machine cutting head. The Li Xiao et al performed simulation research on the random load of the heading machine cutting head by utilizing Rayleigh distribution and Chi 2 distribution. Yang Jian et al propose a method for identifying cut coal rock hardness based on fuzzy criteria, and improve the problem of incomplete information of a single sensor by using multi-sensor information fusion. Armin Salsani et al used an artificial neural network (ann) to predict roadheader performance. SadiEvren Seker et al use an integrated machine learning technique to predict the performance of the roadheader. By predicting the performance of the heading machine, main indexes influencing the performance of the heading machine are obtained, and a basis is provided for optimizing the cutting performance of the heading machine. Zhao Li Juan et al established an overall dynamics model of the heading machine based on Lagrange's principle, obtained the vibration frequency and amplitude response of the heading machine, and studied the vibration characteristics of the whole system. Leizhiyi and the like research the change rule of the cutting load of the heading machine under different coal rock properties. In conclusion, a great deal of research is carried out on the performance prediction and dynamic characteristics of the heading machine, and the parameters of the cutting head are continuously optimized so as to improve the cutting performance of the heading machine and obtain certain results. However, few students research the load identification of the cutting head during cutting, and the research on the automatic control of the heading machine is still blank by adjusting the cutting rotating speed, the swing speed or the drilling speed through the identification of the cutting load.
In order to improve the forming quality of a roadway and the cutting efficiency of the heading machine, reduce the abrasion of a cutting head and prolong the service life of the heading machine, the automation and intellectualization of heading are the development direction of the heading machine in the future. The rotation speed, the swing speed or the drilling speed of the cutting head of the heading machine must be adjusted according to the cutting load, so the identification of the cutting load is very important and necessary.
Because the working environment of the development machine is severe, the structure of the cutting mechanism is complex, and it is difficult to directly measure the dynamic load of the development machine by using a sensor. The cutting load is influenced by the characteristics of cutting rocks and is also related to multi-parameter variables such as cutting working conditions, the cutting head penetration depth, the cutting rotating speed, the cutting swing speed or the drilling speed and the like; therefore, the cutting dynamic load is reflected by identifying the cutting rock hardness based on the multi-parameter influence. The invention provides a novel method for identifying the hardness of cutting rocks based on hydraulic cylinder pressure signals, because the change of the load of a cutting head can cause the corresponding change of the hydraulic cylinder pressure.
Disclosure of Invention
In view of this, the invention aims to provide a method for identifying rock hardness based on a hydraulic cylinder pressure signal and an identification platform thereof, and aims to overcome the defects that cutting rotation speed or swing speed cannot be adjusted in time to adapt to the change of rock characteristics, cutting teeth are easily abraded, broken and a cutter head falls off, so that the cutter head fails and equipment is damaged.
In order to achieve the purpose, the technical scheme is as follows:
the method for identifying the hardness of the rock based on the pressure signal of the hydraulic cylinder comprises the following steps
S1: establishing a function model of the dynamic load of the cutting head and the rock hardness
S1-1: pick load analysis
Carrying out stress analysis according to the cutting state and the tooth form of the cutting tooth, and determining a calculation formula of the cutting tooth load:
in the formula, Gz、Gr、GxRespectively as cutting resistance, feeding resistance and lateral resistance; pkContact strength (MPa); k is a radical of1，k2，k3The influence coefficients of the type, the geometric shape and the cutting angle of the cutting teeth are respectively; t is the average section line spacing (mm); h is the average cut thickness (mm); s is the projection area (mm) of the blunt cutting tooth back cutting edge surface in the traction direction2)；C1、C2And C3Is a coefficient;
wherein the rock contact strength PkExpressed as the Pod hardness coefficient f:
the formula of cutting thickness of the cutting pick is as follows:
wherein v isbThe swing speed (m/s) of the cutting head; n is the rotating speed (r/min) of the cutting head; m is the number of section teeth on the same section line;
the position angle of the ith cutting pick in the cutting area is shown;
s1-2: cutting head load analysis
The load borne by the cutting head is the vector sum of the stress of all cutting picks participating in cutting; simultaneously, carrying out stress analysis on the cutting head to obtain:
the vertical lift force of the cutting head is as follows:
the transverse cutting resistance of the cutting head is as follows:
the cutting head has the following propelling resistance:
in the formula: n isdThe number of cutting teeth participating in cutting; riThe working radius of the ith cutting pick;
where the number of sectional teeth ndThe functional relation between the depth d of the cutting head and the cutting head is as follows:
s1-3: simulating cutter head dynamic load
Programming a simulation program in MATLAB according to a theoretical mathematical model, and researching the influence of the cutting rock characteristic on the cutting dynamic load;
s2: establishing a transfer function model of a pressure signal of a rotary hydraulic cylinder and a dynamic load of a cutting head
S2-1, carrying out stress analysis on the rotary mechanism of the cutting part, and obtaining a thrust moment formula of a hydraulic cylinder on one side of the heading machine:
and a tension moment formula of a hydraulic cylinder on the other side of the heading machine:
and a cutting resistance moment formula of the cutting head:
M3＝FxL0(10)
wherein, FxCutting resistance of the cutting head of the development machine, F1、F2Respectively the pushing force and the pulling force generated by the hydraulic cylinders on the two sides of the rotary table;
s2-2, obtaining a cutting resistance formula of the cutting head according to the moment balance principle:
wherein in the formula, PoilIs the pressure of the rotary hydraulic cylinder, S1Is the cross-sectional area of the cylinder barrel of the hydraulic cylinder, S2Is the cross-sectional area of the hydraulic cylinder rod;
substituting each parameter into (11) and obtaining:
in the formula (12), alpha is a swing angle of the cantilever;
s3, establishing a function model of the rotary hydraulic cylinder and the rock hardness coefficient
According to the internal relation between the pressure of the rotary hydraulic cylinder and the cutting dynamic load, a function model between the pressure signal of the rotary hydraulic cylinder and the rock hardness coefficient is further established, and the function model can be obtained from (1), (2), (5) and (12):
aPk 2+bPk+c＝0
the model utilizes a moment balance principle to establish a moment balance relation between the pressure of the rotary oil cylinder and the cutting resistance of the cutting head, further establishes a function model between the pressure of the rotary oil cylinder and the rock hardness coefficient under multiple parameters by combining the dynamic load change rule of the cutting head, and utilizes the function model to obtain the Python hardness coefficient of the rock.
As a further improvement of the invention, the tooth form of the heading machine pick is a pick-shaped pick.
As a further improvement of the invention, the heading machine for calculating the cutting thickness of the cutting pick in the step S1-1 is in a horizontal cutting working condition.
As a further improvement of the present invention, the revolving mechanism in step S2 is a horizontal cutting condition.
A recognition platform of a method for recognizing rock hardness based on hydraulic cylinder pressure signals comprises a pressure sensor, a data acquisition card and an industrial personal computer, wherein the pressure sensor is installed on a reserved interface of a rotary hydraulic cylinder, signals are transmitted to the industrial personal computer through the data acquisition card used for temporarily storing digital quantity through analog-to-digital conversion, and the industrial personal computer is used for displaying a rock hardness recognition result of an MATlab system to obtain a result, so that cutting parameters of a heading machine are further controlled.
As a further improvement of the invention, the pressure sensor is a mining intrinsically safe pressure sensor with the model of GPD60, the data acquisition card is a data acquisition card with the model of PCI-1716L, 16-bit high-resolution analog-to-digital conversion is adopted, the sampling rate can reach 250kS/s, a 1k sampling FIFO buffer is provided for temporarily storing digital quantity through the analog-to-digital conversion, the industrial personal computer is an ARK-5260 industrial personal computer, the industrial personal computer is provided with an Intel Atom D5101.66GHz dual-core processor, the processing capacity is strong, and a PCIE expansion slot and two PCI expansion slots are arranged in the industrial personal computer, so that the data acquisition card can be conveniently placed.
The invention has the beneficial effects that: simulating the cutting process of the cutting head by a dynamic simulation method; analyzing the change rule of the cutting dynamic load under different rock characteristics; researching the transmission characteristic between the cutting load and the pressure signal of the hydraulic cylinder; constructing a function model between the pressure of the hydraulic cylinder and the hardness coefficient of the cutting rock; developing a cutting rock hardness recognition system in MATLAB;
on the basis of ground test data of 'development of an intelligent ultra-heavy heading machine', the effectiveness and the accuracy of the identification method under specific conditions are verified. The research result shows that: by monitoring the pressure signal of the hydraulic cylinder on line, the method can effectively identify the hardness index of the cutting rock, adjust the rotating speed and the swing speed of the cutting head in time and provide reliable basis for realizing automatic control of the development machine;
the mining intrinsically safe pressure sensor of GPD60, the data acquisition card of PCI-1716L and the industrial personal computer of ARK-5260 are adopted to acquire, store and process data, the industrial personal computer has the advantages of simple structure and stable performance, is suitable for surveying, monitoring and excavating of various coal mine industries, is conveniently connected with various extension devices such as a keyboard and a display, and is convenient for workers to operate.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a force analysis diagram relating to a pick of the present invention;
FIG. 2 is a graph of the present invention relating to stress analysis of a cutting head;
FIG. 3 is a flow chart of the present invention relating to cutting load simulation;
in fig. 4, (a) is a change rule of the lateral resistance of the cutting head with time when the hardness coefficient f of cutting prev is 6, 7, 8, (b) is a change rule of the axial resistance of the cutting head with time when the hardness coefficient f of cutting prev is 6, 7, 8, and (c) is a change rule of the vertical resistance of the cutting head with time when the hardness coefficient f of cutting prev is 6, 7, 8;
FIG. 5 is a stress analysis diagram of the cutting slewing mechanism;
in fig. 6, (a) is a curve of the pressure of the rotary hydraulic cylinder changing with time when the coefficient f of the hardness of the cutting prev is 6; (b) when the cutting Python hardness coefficient f is 7, the pressure intensity of the rotary hydraulic cylinder changes along with time; (c) when the cutting Python hardness coefficient f is 8, the pressure intensity of the rotary hydraulic cylinder changes along with time;
in fig. 7, (a) is a graph showing the change of rock hardness with time when the cut-prev hardness coefficient f is 6; (b) when the coefficient f of the cut Python hardness is 7, the rock hardness is a curve changing along with time; (c) when the coefficient f of the cut Python hardness is 8, the rock hardness is a curve changing along with time.
Detailed Description
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
In order to make the technical solutions better understood by those skilled in the art, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only partial embodiments of the present application, but not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
The method for identifying the hardness of the rock based on the pressure signal of the hydraulic cylinder comprises the following steps:
s1: establishing a function model of the dynamic load of the cutting head and the rock hardness
S1-1: cutting tooth load analysis:
as shown in fig. 1, when the cutting pick acts on the rock, the cutting pick can receive the reaction force of the rock, and the force applied to the cutting pick is respectively decomposed in the cutting direction, along the radius direction of the cutting head and in the lateral direction parallel to the axis of the cutting head. Analyzing the stress of the cutting pick in a cutting state;
for a pick, the cutting load is as follows:
in the formula, Gz、Gr、GxRespectively as cutting resistance, feeding resistance and lateral resistance; pkContact strength (MPa); k is a radical of1，k2，k3Respectively the type, geometry, or cut-off angle of the cutting pickA coefficient of loudness; t is the average section line spacing (mm); h is the average cut thickness (mm); s is the projection area (mm) of the blunt cutting tooth back cutting edge surface in the traction direction2)；C1、C2And C3Is a coefficient.
Wherein the rock contact strength PkIt can be expressed as the Pod hardness coefficient f, as follows:
however, because the cutting working conditions of the heading machine are different, and the cutting thickness h of the cutting pick is different, when the heading machine is in the horizontal cutting working condition, the cutting thickness of the cutting pick is as follows:
wherein v isbThe swing speed (m/s) of the cutting head; n is the rotating speed (r/min) of the cutting head; m is the number of section teeth on the same section line;
the position angle of the ith cutting pick in the cutting area is shown;
it can be seen that the stress of a single cutting pick is not only related to the parameters of the cutting pick, but also related to the rotating speed of the cutting head, the swing speed or drilling speed of the cantilever and the characteristics of the rock to be cut.
S1-2: cutting head load analysis
As shown in fig. 2, the load borne by the cutting head is the vector sum of the forces of all cutting picks participating in cutting, and the number of cutting picks participating in cutting is mainly related to two factors: firstly, the cutting head enters the rock wall deeper, the more the cutting head enters the rock wall, the more the cutting teeth participating in cutting; second, the position angle of the cutting pick, each cutting pick on the cutting head has its corresponding position angle φiAnd in the rotating cutting process of the cutting head, only the half side of the cutting head contacts the rock wall to participate in cutting. Therefore, whether the cutting pick is in the cutting area or not can be judged through the cutting head penetration depth and the position angle of the cutting pick, and the cutting pick in the cutting area at the same moment is stressed to carry out vector summation so as to obtainThe dynamic load of the cutting head is stressed when the cutting head rotates to a certain position at any time;
the vertical lift force of the cutting head is as follows:
the transverse cutting resistance of the cutting head is as follows:
the cutting head has the following propelling resistance:
in the formula: n isdThe number of cutting teeth participating in cutting; riThe working radius of the ith cutting pick;
the number of the cutting picks participating in cutting is related to the penetration depth of the cutting head, the larger the penetration depth of the cutting head is, the more the number of the cutting picks participating in cutting is, and the assumed penetration depth d (mm) of the cutting head is equal to the number n of the cutting teeth participating in cuttingdThere is a functional relationship between: n isdG (d). Wherein each cutting pick number n of the heading machineiAll corresponding to a determined interaxial distance value l (D + l ═ D, D is the cutting head length, mm), and obtaining n according to the least square methoddFunctional relationship with d:
when the cutting head drills the undercut longitudinally,
when the cutting head horizontally swings or vertically swings to cut,
taking a home-made EBZ160 type heading machine as an example, the length of the cutting head is 975mm, and the relation between the cutting head penetration depth and the cutting pick number is obtained according to the cutting pick position design parameters and is shown in Table 1:
TABLE 1 relationship of cutting head penetration depth to cutting pick count
Table 1The relationship between the depth of cutting head and thenumber of picks
Fitting by a least square method to obtain a function relation between the number of cutting teeth of the working area and the penetration depth of the cutting head under the working condition of horizontal swing or vertical swing as follows:
the load calculation formula of the cutting head and the cutting tooth calculation formula can be used for obtaining the load of the cutting head of the heading machine, and the magnitude of the dynamic load of the cutting head of the heading machine is different under different cutting working conditions of the heading machine, the depth of the cutting head, the rotating speed of the cutting head, the swing speed or drilling speed of the cutting head and the hardness of cutting rocks.
S1-3: simulation research on dynamic load of cutting head
As shown in fig. 3, the above analysis can obtain the influence of the cutting head penetration depth, the rotating speed, the swing speed or the drilling speed and the cutting rock hardness on the dynamic load of the cutting head under different cutting conditions, and a program flow chart is selected for programming a simulation program in MATLAB according to a theoretical mathematical model;
as shown in fig. 4, taking a horizontal cutting working condition as an example, the influence of the characteristics of the cut rock on the cutting dynamic load is studied, and when the heading machine is cutting the rock wall, the rock wall is not composed of rocks with single hardness, but is distributed by layers of rocks with various hardnesses. Along with different hardness of cutting rocks, the load of the cutting head is changed continuously. When the cutting head completely enters a rock wall and the cutting arm drives the cutting head to transversely cut, setting the swing speed of the cutting head as v is 1.5m/min, setting the rotation speed of the cutting head as n is 46r/min, respectively cutting rocks with the hardness coefficient f of 6, f is 7 and f is 8, and researching the change rule of the cutting dynamic load of the development machine;
in the horizontal cutting process of the heading machine, when the same cutting head penetration depth, cutting rotating speed and cutting swinging speed are adopted to respectively cut rocks with different hardness, the overall stress of the cutting head in three directions is increased along with the increase of the hardness of the cut rocks;
the load simulation curve shows that the force borne by the whole cutting head fluctuates irregularly, and the force changes, so that the load borne by the cutting head is a dynamic load; wherein the traction resistance of the cutting head is the largest, and the lateral resistance is always at a lower level. When the heading machine cuts rocks with different characteristics, the cutting difficulty is increased along with the increase of the hardness of the rocks, and the load borne by the cutting head is obviously increased along with the increase of the hardness coefficient of the cut rocks.
S2: establishing a transfer function model of a pressure signal of a rotary hydraulic cylinder and a dynamic load of a cutting head
S2-1, connecting a pair of symmetrically distributed hydraulic cylinders between the rotary table and the machine body, fixedly connecting the cutting arm with the rotary table, and driving by the hydraulic cylinders, wherein in the horizontal cutting process, the hydraulic cylinder on one side is lengthened, the hydraulic cylinder on the other side is synchronously shortened, and the rotary table is driven to rotate by the cooperative motion to drive the cutting arm to swing around the rotation center of the cutting arm, so that the force acts on the cutting mechanism;
as shown in FIG. 5, wherein O1Is the rotation center point of the rotary table; o is2Is a connecting point of the right hydraulic cylinder and the machine body; o is3Is the connection point of the left hydraulic cylinder and the machine body, C is the connection point of the right hydraulic cylinder and the rotary table, B is the connection point of the left hydraulic cylinder and the rotary table, A is the stress point of the cutting head, R is the rotary radius of the rotary table, α is the swing angle of the cutting arm, and L is the swing angle of the cutting arm1And L2The total length of the hydraulic cylinders on the two sides changes along with the swing angle of the cutting arm: l is1＝CO2，L2＝BO3；O1O3＝O1O2＝Lr，O1A＝L0，<BO1O3＝ε；<CO1O2＝γ；<O1CO2＝φ1；<O1BO3＝φ2；
Take the horizontal swinging cutting process as an example. FxThe cutting resistance of the cutting head in the horizontal direction when the heading machine works; f1、F2Respectively the pushing force and the pulling force generated by the hydraulic cylinders at the two sides of the rotary table. When the cutting arm transversely swings to the left, hydraulic oil enters the head of the hydraulic cylinder on the right side to push the rotary table, and hydraulic oil enters the connecting rod port of the hydraulic cylinder on the left side to pull the rotary table. When the cutting arm swings to the right, the stress situation is opposite to the analysis;
the thrust moment of the hydraulic cylinder on one side is calculated by taking the center O of the rotary table as a base point as shown in a formula (8):
the moment of tension of the hydraulic cylinder on the other side is shown in formula (9):
the cutting resistance moment of the cutting head is shown as the formula (10):
M3＝FxL0(10)
s2-2, according to the moment balance principle, when the heading machine is in a stable cutting state, the horizontal cutting resistance of the cutting head in the horizontal direction is shown as a formula (11):
wherein, PoilIs the pressure of the rotary cylinder, S1Is the cross-sectional area of the cylinder barrel of the hydraulic cylinder, S2Is the cross-sectional area of the cylinder rod of the hydraulic cylinder. Phi is a1,φ2This can be obtained from equation (12):
wherein: l is1And L2Can be obtained by the cosine theorem, as shown in equation (13):
wherein:
alpha is the swing angle of the cantilever, and can be obtained by the swing speed of the cutting head:
the following equations (11) to (14) can be obtained:
s3, establishing a function model of the rotary hydraulic cylinder and the rock hardness coefficient
When the heading machine cuts rock walls with different hardness, the transverse cutting resistance F borne by the cutting headxVarying therewith, in order to balance the transverse cutting resistance, the thrust F of the two rotary cylinders1Or pulling force F2A change occurs. Therefore, the pressure of the rotary oil cylinder can represent the transverse cutting resistance of the load of the cutting head, and further reflect the hardness of the cutting rock wall.
Aiming at the situation, the pressure of the rotary hydraulic cylinder is monitored by a sensor, and the current transverse cutting resistance F borne by the cutting head is calculatedx. And further establishing a function model between the pressure signal of the rotary hydraulic cylinder and the rock hardness coefficient according to the internal relation between the pressure of the rotary hydraulic cylinder and the cutting dynamic load.
From (1) (2), (5) and (16):
aPk 2+bPk+c＝0
in the process of horizontally swinging the cutting head to cut the rock wall, as the cutting head is different in penetration depth, rotating speed, swinging speed and rock hardness, the transverse cutting resistance borne by the cutting head is continuously changed, so that the pressure of the rotary oil cylinder is continuously changed, and the pressure of the rotary oil cylinder can be used as a monitoring quantity for representing the dynamic load of the cutting head. By utilizing a moment balance principle, a moment balance relation between the pressure of the rotary oil cylinder and the cutting resistance of the cutting head is established, a function model between the pressure of the rotary hydraulic cylinder and the rock hardness coefficient under multiple parameters is further established by combining a dynamic load change rule of the cutting head, and when the heading machine carries out horizontal cutting, the function model can be utilized to obtain the Python hardness coefficient f of the rock by monitoring the pressure signal of the rotary hydraulic cylinder.
A recognition platform of a method for recognizing the hardness of rock based on a hydraulic cylinder pressure signal comprises a pressure sensor, a data acquisition card and an industrial personal computer, wherein under the horizontal cutting working condition of a heading machine, the pressure of a rotary hydraulic cylinder of the heading machine is determined as a signal for reflecting the cutting load, the pressure sensor is installed on a reserved interface of a rotary oil cylinder, the signal is transmitted to the industrial personal computer through the data acquisition card, and a rock hardness recognition system in the industrial personal computer realizes recognition of the hardness of the cut rock and displays a recognition result.
The mining intrinsically safe pressure sensor with the model number of GPD60 is selected, and has the advantages of simple structure and stable performance, the power supply voltage DC 12-28V, the precision (+ 0.5% F.S), the measuring range 0-60 MPA and the output signal 0-5V, and is suitable for surveying, monitoring and excavating in various coal mine industries;
the data acquisition card with the model of PCI-1716L is selected, has 16-bit high-resolution analog-to-digital conversion, the sampling rate of the data acquisition card can reach 250kS/s, and is provided with a 1k sampling FIFO buffer which is used for temporarily storing digital quantity through analog-to-digital conversion;
the industrial personal computer is used for displaying the rock hardness recognition result of the MATlab system to obtain a result, so that the cutting parameters of the heading machine are further controlled; the industrial personal computer is selected as ARK-5260, is provided with an Intel Atom D5101.66GHz dual-core processor, is high in processing capacity, and is internally provided with one PCIE expansion slot and two PCI expansion slots, so that the data acquisition card can be conveniently placed. In order to facilitate networking, the industrial computer supports 2GLAN and 5 USB 2.0 interfaces, and can be connected with various expansion devices such as a keyboard and a display to facilitate operation of workers.
In order to verify the effectiveness and the accuracy of the proposed rock wall hardness identification method, data collected by a ground test of intelligent ultra-heavy rock heading machine development are analyzed. Generally, roadways developed by coal mines and underground works are composed of rocks of different hardness. Therefore, the heading machine cuts rock walls with the hardness grades f equal to 6, 7 and 8 under the horizontal cutting working condition, the penetration depth, the rotating speed and the swing speed of the cutting head are respectively set, and the sampling frequency is 1000 Hz;
as shown in fig. 6, setting the rotation speed n of the cutting head to be 46r/min, the rotation speed v of the cutting head to be 1.5-2.0 m/min, the penetration depth d of the cutting head to be 800-920 mm, respectively cutting the rocks with the straight hardness coefficients f of 6, 7 and 8, and collecting pressure signals of a rotary oil cylinder;
in the cutting process, the hardness of the cutting rock has obvious influence on the dynamic load of the cutting head. The result shows that under the constant cutting rock penetration depth, cutting rotating speed and cutting swing speed, the pressure of the rotary hydraulic cylinder is increased along with the increase of the hardness of the cutting rock.
As shown in fig. 7, programming a function model between the established pressure signals and the rock hardness coefficient by using MATLAB software, designing a rock hardness recognition system, and verifying results by using 3 groups of collected pressure signals;
FIG. 7 shows the recognition results of different cutting rock hardnesses, and in FIG. 7(a), the recognition results of rock hardness coefficients fluctuate within the range of 5.7-6.4; in FIG. 7(b), the recognition result of the rock hardness coefficient fluctuates within a range of 6.6 to 7.4; in FIG. 7(c), the recognition result of the rock hardness coefficient fluctuates within a range of 7.6 to 8.4. The comparison shows that when the heading machine cuts horizontally, the rock hardness identification result based on the function model fluctuates up and down continuously near the actual hardness, and although a certain identification error exists, the rock hardness identification still has high effectiveness. Therefore, reliable basis is provided for the development machine to realize automatic cutting.
Claims (6)
1. The method for identifying the hardness of the rock based on the pressure signal of the hydraulic cylinder is characterized by comprising the following steps of: comprises the following steps
S1: establishing a function model of the dynamic load of the cutting head and the rock hardness
S1-1: pick load analysis
Carrying out stress analysis according to the cutting state and the tooth form of the cutting tooth, and determining a calculation formula of the cutting tooth load:
in the formula, Gz、Gr、GxRespectively as cutting resistance, feeding resistance and lateral resistance; pkContact strength (MPa); k is a radical of1，k2，k3The influence coefficients of the type, the geometric shape and the cutting angle of the cutting teeth are respectively; t is the average section line spacing (mm); h is the average cut thickness (mm); s is the projection area (mm) of the blunt cutting tooth back cutting edge surface in the traction direction2)；C1、C2And C3Is a coefficient;
wherein the rock contact strength PkExpressed as the Pod hardness coefficient f:
the formula of cutting thickness of the cutting pick is as follows:
wherein v isbThe swing speed (m/s) of the cutting head; n is the rotating speed (r/min) of the cutting head; m is the number of section teeth on the same section line;
the position angle of the ith cutting pick in the cutting area is shown;
s1-2: cutting head load analysis
The load borne by the cutting head is the vector sum of the stress of all cutting picks participating in cutting; simultaneously, carrying out stress analysis on the cutting head to obtain:
the vertical lift force of the cutting head is as follows:
the transverse cutting resistance of the cutting head is as follows:
the cutting head has the following propelling resistance:
in the formula: n isdThe number of cutting teeth participating in cutting; riThe working radius of the ith cutting pick;
where the number of sectional teeth ndThe functional relation between the depth d of the cutting head and the cutting head is as follows:
s1-3: simulating cutter head dynamic load
Programming a simulation program in MATLAB according to a theoretical mathematical model, and researching the influence of the specific hardness of the cutting rock on the cutting dynamic load;
s2: establishing a transfer function model of a pressure signal of a rotary hydraulic cylinder and a dynamic load of a cutting head
S2-1, carrying out stress analysis on the rotary mechanism of the cutting part, and obtaining a thrust moment formula of a hydraulic cylinder on one side of the heading machine:
and a tension moment formula of a hydraulic cylinder on the other side of the heading machine:
and a cutting resistance moment formula of the cutting head:
M3＝FxL0(10)
wherein, FxCutting resistance of the cutting head of the development machine, F1、F2Respectively the pushing force and the pulling force generated by the hydraulic cylinders on the two sides of the rotary table;
s2-2, obtaining a cutting resistance formula of the cutting head according to the moment balance principle:
wherein in the formula, PoilIs the pressure of the rotary hydraulic cylinder, S1Is the cross-sectional area of the cylinder barrel of the hydraulic cylinder, S2Is the cross-sectional area of the hydraulic cylinder rod;
substituting each parameter into (11) and obtaining:
in the formula (12), alpha is a swing angle of the cantilever;
s3, establishing a function model of the rotary hydraulic cylinder and the rock hardness coefficient
According to the internal relation between the pressure of the rotary hydraulic cylinder and the following dynamic load, a function model between the pressure signal of the rotary hydraulic cylinder and the rock hardness coefficient is further established, and the function model can be obtained from (1), (2), (5) and (12):
aPk 2+bPk+c＝0
the model utilizes a moment balance principle to establish a moment balance relation between the pressure of the rotary oil cylinder and the cutting resistance of the cutting head, further establishes a function model between the pressure of the rotary oil cylinder and the rock hardness coefficient under multiple parameters by combining the dynamic load change rule of the cutting head, and utilizes the function model to obtain the Python hardness coefficient of the rock.
2. The method of identifying rock hardness based on hydraulic cylinder pressure signals of claim 1, wherein the tooth form of the roadheader pick is a pick.
3. The method for identifying rock hardness based on hydraulic cylinder pressure signals according to claim 1, wherein the roadheader for which the cutting pick cutting thickness is calculated in step S1-1 is in a horizontal cutting condition.
4. The method for identifying rock hardness based on hydraulic cylinder pressure signals according to claim 1, wherein the slewing mechanism is a horizontal cutting operation in step S2.
5. An identification platform of the method for identifying the hardness of the rock according to claim 1, comprising a pressure sensor, a data acquisition card and an industrial personal computer, wherein the pressure sensor is installed on a reserved interface of the rotary hydraulic cylinder, the signal is transmitted to the industrial personal computer through the data acquisition card for temporarily storing digital quantity through analog-to-digital conversion, and the industrial personal computer is used for displaying the rock hardness identification result of the MATlab system and further controlling the cutting parameters of the heading machine according to the result.
6. The identification platform of the method for identifying the hardness of the rock based on the pressure signal of the hydraulic cylinder according to claim 5, wherein the pressure sensor is a mining intrinsically safe pressure sensor with the model number of GPD60, the data acquisition card is a data acquisition card with the model number of PCI-1716L, the data acquisition card has 16-bit high-resolution analog-to-digital conversion, the sampling rate of the data acquisition card can reach 250kS/s, the industrial personal computer is a sampling FIFO buffer with 1k and is used for temporarily storing digital quantity through the analog-to-digital conversion, the industrial personal computer is an industrial personal computer with the model number of ARK-5260, the industrial personal computer is provided with an Intel Atom Dcom 5101.66GHz dual-core processor, the processing capability is high, and a PCIE expansion slot and two PCI expansion slots are arranged in the industrial.
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