CN113051756B - Virtual-real fusion coal mining machine memory cutting test system and method - Google Patents
Virtual-real fusion coal mining machine memory cutting test system and method Download PDFInfo
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Abstract
The invention provides a virtual-real fused memory cutting test system and method for a coal mining machine. The coal mining machine is installed on the test bench, a worker operates the coal mining machine to perform demonstration cutter operation, a sensor installed on the coal mining machine transmits signals to a virtual test scene in real time, the virtual coal mining machine is driven to operate in a virtual coal seam, and various data are displayed for the worker to refer to. The autonomous prediction data for memorizing the cutting come from a real coal mining machine controller, the virtual coal mining machine is driven to operate, the memorized cutting effect is displayed on the test board, the prediction data and the manual operation data can be derived for comparative analysis, and the memorized cutting effect is verified. The scheme solves the problems that the current testing memory cutting can only be carried out in the underground actual environment, huge manpower and material resources are consumed in the testing process, the actual underground environment risk factors are many, the danger coefficient is high, the testing is difficult, the feasibility is low and the like.
Description
Technical Field
The invention relates to the technical field of performance test simulation, in particular to a virtual-real fusion coal mining machine memory cutting test system and method.
Background
In the fully mechanized mining face, a coal mining machine is used as a core device, and the production benefit of a mine is severely limited by the automation degree of the coal mining machine. The key for realizing the automation of the whole working face is to comprehensively, quickly and accurately acquire various operating parameters of the coal mining machine and realize the real-time and accurate control of the operating posture through information fusion processing. On the basis of acquiring all the operating parameters of the coal mining machine, if all the information of the coal mining machine can be reflected in a set of model system in real time, the intelligent control visualization degree of the coal mining machine can be greatly improved, and further theoretical research or experimental operation is facilitated.
At present, the current coal rock identification technology is still not industrially applied, and the fully mechanized mining face generally adopts a memory cutting and manual intervention method as a main flow mode of long-term operation in the coal mining process, so the memory cutting technology of a coal mining machine is gradually matured. In various theoretical schemes, a real three-dimensional scene similar to a panorama and virtual equipment of a fully-mechanized coal mining face can be constructed by the virtual reality technology, the coal mining process and the operation of related equipment are simulated, the application potential of quick reflection, accuracy and intuition is shown, and the method has important significance for monitoring and judging the relative pose state of the fully-mechanized coal mining three-machine equipment, ensuring the correctness of the action of each equipment in the coal mine production process and improving the safety, high efficiency and intelligent level of the fully-mechanized coal mining face.
In the prior art, the utility model discloses a "realize experimental system of coal-winning machine intelligent control of multi-information fusion" of publication No. 201620402537.5, including data acquisition system, computer human-computer interaction interface, machine-mounted controller and motion actuating mechanism, can verify the intelligent control method of coal-winning machine of multi-information fusion under the laboratory condition. The invention discloses a memory cutting method research of a virtual coal mining machine with the publication number of 201611034015.5, which drives a virtual prototype of the coal mining machine in real time according to working condition parameters of the coal mining machine, draws fully mechanized coal mining working faces with different geological conditions and realizes real reproduction of coal mining working states.
However, the method has the defects that only a test method is provided and is simply verified, the test result cannot be effectively combined with the actual production, and a test system scheme for visually analyzing the memory cutting technology, quickly and conveniently testing the performance of the coal cutter controller and verifying the memory cutting effect is lacked.
Disclosure of Invention
The invention overcomes the defects in the prior art and provides a system scheme for carrying out a memory cutting test of a coal mining machine in a virtual reality environment. The scheme solves the problems that the current testing memory cutting can only be carried out in the underground actual environment, huge manpower and material resources are consumed in the testing process, the actual underground environment risk factors are many, the danger coefficient is high, the testing is difficult, the feasibility is small and the like.
In order to solve the technical problems, the invention provides the following technical scheme: a coal mining machine memory cutting test system with virtual-real fusion comprises: the system comprises a virtual test scene, a virtual-real interaction system and a test bench;
the virtual test scene is constructed according to different underground environments applied by actual coal mining machines to be tested and comprises a virtual coal seam bottom plate, virtual equipment and a scene display device, wherein the virtual equipment comprises a virtual scraper conveyor and a virtual coal mining machine; the virtual-real interaction system comprises a physical data module, a virtual-real interaction module and a virtual data module; the test bench is arranged on a horizontal ground and comprises a coal cutter, various sensors, an adjusting frame and a supporting frame which are matched with a tested coal cutter controller;
the coal mining machine is arranged on the support frame through the adjusting frame, and idling and mining height adjustment are performed; the adjusting frame consists of a supporting frame, a pitch angle push rod and a roll angle push rod, the pitch angle push rod and the roll angle push rod can adjust the pitch angle and the roll angle of the coal mining machine in real time under the control of virtual coal mining machine data, and the attitude change of the coal mining machine in the operation of an underground actual working environment is simulated; the coal mining machine is additionally provided with a sensor, and the type of the sensor at least comprises a traction part shaft encoder, a rocker arm tilt angle sensor and strapdown inertial navigation;
the virtual coal seam floor model obtains the law of corresponding coal seam trend change based on geological detection data and operation data of a real underground experienced coal mining machine driver, and obtains coal seam data points according to a similar design method; simulating the inclination state of the top floor and the bottom floor of a real underground coal seam by using the floor model; the virtual coal mining machine and the virtual scraper conveyor are constructed based on the geometric overall dimensions of the coal mining machine to be tested and the scraper conveyor matched with the coal mining machine;
the scene display comprises a coal cutter cutting curve generation panel and a data display panel; the cutting curve generation panel of the coal mining machine is used for drawing a cutting track of a drum of the coal mining machine, displaying the cutting curve in real time in the running process of the virtual coal mining machine and realizing the visualization of the whole coal cutting process; the data display panel is used for linking and displaying the running speed of the virtual coal mining machine, the angles of the left rocker arm and the right rocker arm, the heights of the left roller and the right roller, the pitch angle of the machine body and the roll angle with the variable of the sensor, so that the real-time display and monitoring of the pose information of the coal mining machine to be tested are realized;
the physical data module is used for receiving real-time machine body inclination angle information of the coal mining machine in the virtual-real interaction module, controlling the movement of a pitch angle push rod and a roll angle push rod of an adjusting frame of the test bench, and simulating the working posture change of the coal mining machine in the underground real environment in real time; the virtual-real interaction module is used for carrying out data interaction with the physical data module and the virtual data module, real-time data and control instructions are transmitted between the physical data module and the virtual data module through the virtual-real interaction module, the real-time data are sent to the virtual data module, and the virtual coal mining machine is driven to act and display; the virtual data module is used for receiving the real-time pose and the running speed of the coal mining machine to be tested, transmitting the pose and the running speed to a virtual test scene, and driving the virtual coal mining machine to act and display the pose and the running speed in real time.
Adding rigid body and collision body components on the virtual coal seam floor model to simulate the supporting effect of a real coal seam floor on a scraper conveyor; the method comprises the following steps that 1:1 modeling is carried out on a virtual coal cutter and a virtual scraper conveyor in UG software according to the model and the geometric overall dimension of an actual tested model, the model is led into 3D MAX software after modeling is completed, the model format is converted into Fbx format, finally, models in Fbx format of each part of the coal cutter and the scraper conveyor are led into Unity3D, and the construction of the coal cutter and the scraper conveyor in a virtual test scene is completed;
compiling C # scripts to realize the control of the walking, acceleration and deceleration, the lifting of the left rocker arm and the right rocker arm and the rotation of the roller of the virtual coal mining machine according to the test requirements; adding a control script for the virtual scraper conveyor to enable the virtual scraper conveyor to be paved on a coal seam bottom plate with high and low fluctuation in a self-adaptive manner;
according to the test requirement, writing a C # program for the virtual coal mining machine, reserving attitude driving variables of a pitch angle and a roll angle, and associating the attitude driving variables with the real-time position and the attitude data volume of the actual coal mining machine to be tested through a virtual-real interaction system; the method specifically comprises the following steps: during testing, acquiring real-time pose data of the coal mining machine to be tested through a sensor arranged on the coal mining machine to be tested, transmitting the real-time pose data to a virtual data module through a virtual-real interaction module, processing the real-time pose data of the coal mining machine to assign a posture driving variable corresponding to the virtual coal mining machine, and driving the virtual coal mining machine to synchronously perform position posture actions;
rigid body and collision body components are added in a virtual coal mining machine and a virtual scraper conveyor to simulate the interaction of a real coal mining machine with a coal bed and the scraper conveyor, so that the virtual scraper conveyor can be flatly paved on a coal bed bottom plate with high and low fluctuation in a self-adaption mode, a sliding shoe of the virtual coal mining machine is arranged on a chute coal shoveling plate of the virtual scraper conveyor, and a machine body is parallel to the scraper conveyor.
The physical data module receives real-time pose and running speed data of a coal mining machine to be tested, which are acquired by a sensor mounted on the coal mining machine, and sends the real-time pose and running speed data to the virtual-real interaction module, and the virtual-real interaction module sends the real-time data to the virtual data module to drive the virtual coal mining machine to act and display; meanwhile, the physical data module receives real-time machine body inclination angle information of the coal mining machine in the virtual-real interaction module, controls the movement of a pitch angle push rod and a roll angle push rod of an adjusting frame of the test bench, and simulates the posture change of the coal mining machine working in the underground real environment in real time;
the virtual data module is in data communication and information exchange with the virtual-real interaction module and the virtual test scene; a sensor installed on the coal mining machine collects real-time pose and running speed data of the coal mining machine to be tested and transmits the data to a physical data module, the physical data module transmits the real-time data to a virtual data module through a virtual-real interaction module, and the virtual data module transmits the real-time pose and running speed data of the coal mining machine to a virtual test scene after receiving the real-time pose and running speed data of the coal mining machine to be tested, and drives the virtual coal mining machine to act and display the data in real time.
The traction part shaft encoder is used for measuring the rotating speed of a traction motor of the coal mining machine and calculating the speed of the coal mining machine; the rocker arm inclination angle sensor is used for measuring the angles of the left rocker arm and the right rocker arm and calculating mining height data of the roller; the strapdown inertial navigation is used for measuring a pitch angle, a roll angle and a real-time space three-dimensional coordinate of a body of the coal mining machine.
In order to solve the technical problems, the invention provides the following technical scheme: a virtual-real fusion coal mining machine memory cutting test method utilizes the virtual-real fusion coal mining machine memory cutting test system in the technical scheme to carry out tests, and comprises the following steps:
step 1: constructing a virtual test scene; acquiring operation data and geological detection data of a driver of the underground coal mining machine according to the coal seam where the coal mining machine to be tested is located, and establishing a virtual coal seam floor model; constructing a virtual coal cutter and a virtual scraper conveyor, carrying out 1:1 modeling in UG software according to the models and the geometric overall dimensions of the actual coal cutter and the scraper conveyor, importing the models into 3D MAX software after the modeling is finished, converting the model formats into Fbx formats, importing all parts Fbx format models into Unity3D, and finishing the construction of equipment models in a virtual test scene;
after the virtual test scene is built, a coal mining machine and a scraper conveyor script assembly are respectively created and added to control the movement of an object, and a C # script is compiled according to the test requirement to realize the control of the walking, acceleration and deceleration, the lifting of a left rocker arm and a right rocker arm and the rotation of a roller of the virtual coal mining machine;
rigid body and collision body components are added at key parts of a virtual coal mining machine and a virtual scraper conveyor, and the interaction between a real coal mining machine and a coal bed and the scraper conveyor is simulated, so that the virtual scraper conveyor can be flatly laid on a coal bed bottom plate with high and low fluctuation in a self-adaptive manner, a sliding shoe of the virtual coal mining machine can be laid on a chute coal shoveling plate of the virtual scraper conveyor, and a machine body is parallel to the scraper conveyor;
according to the test requirement, writing a C # program for the virtual coal mining machine, reserving pitch angle and roll angle attitude driving variables, and associating the attitude variables with the real-time position and attitude data volume of the coal mining machine to be tested through a virtual-real interaction system; during testing, the sensor acquires real-time pose data of a coal mining machine to be tested, the real-time data is transmitted to the virtual data module through the physical data module, the virtual data module processes the real-time pose data of the coal mining machine to be tested and assigns the processed real-time pose data to a posture driving variable corresponding to the virtual coal mining machine, and the virtual coal mining machine is driven to synchronously perform position posture actions;
in the OnGUI method, a data display panel is created by writing character strings, the running speed of a virtual coal mining machine, the angles of a left rocker arm and a right rocker arm, the heights of a left roller and a right roller, the pitch angle of a machine body and the roll angle are linked with sensor variables and displayed, and the real-time display and monitoring of the pose information of the coal mining machine are realized;
step 2: installing a test bench; selecting coal mining machines of corresponding models according to requirements of a coal mining machine operated on a test fully mechanized mining face and a coal mining machine controller to be tested, and installing the coal mining machines on an adjusting frame on a test bench which is arranged on a horizontal ground;
the coal mining machine is erected by the adjusting frame, idles on the rack and adjusts the mining height, and corresponding sensors are arranged on key positions of the coal mining machine; a shaft encoder is arranged on a motor shaft of a traction part of the coal mining machine and is used for measuring the rotating speed of the traction motor of the coal mining machine; the middle parts of the left rocker arm and the right rocker arm are provided with tilt sensors for measuring the angles of the left rocker arm and the right rocker arm; the method comprises the following steps that strapdown inertial navigation is installed on the upper portion of a coal mining machine body and used for measuring a pitch angle, a roll angle and a real-time space three-dimensional coordinate of the coal mining machine body; meanwhile, a controller to be tested is installed on the coal mining machine;
and step 3: starting the test; collecting ten-tool data sets in the actual underground production process, and performing demonstration tool training on a coal mining machine controller according to the first five-tool data of the data sets; operating a traction motor of the coal mining machine according to the data set and adjusting the mining height of the left rocker arm and the right rocker arm, transmitting signals of a sensor on the coal mining machine to a virtual test scene through a virtual-real interaction channel, and driving the virtual coal mining machine to operate on a virtual coal seam bottom plate; the method comprises the steps that the operation state of a virtual coal mining machine is displayed in real time and a cutting curve is displayed on the picture in a virtual test scene, meanwhile, inclination angle change information generated by the virtual coal mining machine operating on a virtual coal seam bottom plate is transmitted to a test table adjusting frame through a virtual-real interaction system, a pitch angle push rod and a roll angle push rod are controlled to move, and the posture change of the coal mining machine working in a real underground environment is simulated in real time; the data display panel displays the position, the speed, the left and right rocker arm angles, the left and right roller heights, the pitch angle of the machine body and the roll angle information of the current virtual coal mining machine in real time for workers to operate and refer to;
the coal mining machine controller autonomously predicts and generates data of the next knife based on the data of the demonstration knife, generates data of the sixth knife according to the data of the first five knives operated by workers, generates data of the seventh knife according to the data of the second knife and the sixth knife, and completes the prediction of the data of the fifth knife by analogy; the method comprises the steps that a coal mining machine controller obtains position information of a virtual coal mining machine in an autonomous prediction process, prediction cutter data drive the virtual coal mining machine to run in a virtual test scene, the virtual test scene displays a cutting curve, a data display panel displays real-time pose information, meanwhile, an actual coal mining machine is driven to run on a test bench, and the effect of cutting is displayed and memorized;
and 4, step 4: the test is finished; and exporting the five-cutter data automatically predicted by the coal mining machine controller through the Unity software, and comparing the data set of the predicted cutter with the data set of the next five cutters actually operated by underground workers through MATLAB software to obtain the effect analysis of the memory cutting of the coal mining machine controller.
Compared with the prior art, the virtual-real fused coal mining machine memory cutting test system and method provided by the invention have the following beneficial effects:
1. according to the method, a coal seam floor model is constructed, based on geological detection data and operation data of a real underground experienced coal mining machine driver, a rule of corresponding coal seam trend change is obtained, and then a coal seam data point is obtained according to a similar design method. When the coal mining machine and the scraper conveyor model are built, the geometric appearance and the action flow of actual equipment are completely referred, so that the reliability of the test in a virtual test scene is high. According to the coal seam condition of the coal mine to be researched and the different types of the coal mining machines, researchers can correspondingly modify the coal seam condition and the different types of the coal mining machines to be researched, and a virtual test scene is quickly constructed so as to complete the performance test of the coal mining machine controller with the specific type under the specific coal seam condition;
2. the performance of the coal mining machine controller is tested by combining the virtual reality technology and the memory cutting technology, and a tester can test the coal mining machine controller without actually operating the coal mining machine in a real underground environment. In addition, the test system and the test method have strong repeatability;
3. the invention realizes the real-time visual display of the three-dimensional picture and the related data of the pose state of the coal mining machine in the test process by means of the virtual reality display technology, and researchers can carry out panoramic and visual observation on the action and the pose state of the coal mining machine in the test process; in addition, on the basis of the software support of the Unity3d, researchers can acquire more types of test data in a virtual test scene by adding scripts and the like according to test requirements, so that the researchers can complete tests and perform related extended analysis conveniently;
4. the method can compare the self-predicted memory cutting data of the coal mining machine with the manual cutting data. The performance of the coal mining machine controller is tested and the effect of memorizing cutting is verified by carrying out quantitative comparison, such as scoring and evaluating the closeness of the cutting curves of the coal mining machine controller and the safety degree of the two cases.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
fig. 1 is a schematic structural diagram of a virtual-real fusion coal mining machine memory cutting test system provided by the invention.
Fig. 2 is a schematic diagram of a virtual-real fusion coal mining machine memory cutting test system provided by the invention.
Fig. 3 is an installation schematic diagram of a test bench of a virtual-real fusion coal mining machine memory cutting test system provided by the invention.
Fig. 4 is a logic schematic diagram of a virtual-real fusion coal mining machine memory cutting test method provided by the invention.
Detailed Description
For a more clear understanding of the technical features, objects and effects of the present invention, embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
As shown in fig. 1 and 2, the invention provides a virtual-real fused memory cutting test system for a coal mining machine, which comprises: the system comprises a virtual test scene, a virtual-real interaction system and a test bench;
the virtual test scene is constructed according to different underground environments applied by actual coal mining machines to be tested and comprises a virtual coal seam bottom plate, virtual equipment and a scene display device, wherein the virtual equipment comprises a virtual scraper conveyor and a virtual coal mining machine; the virtual-real interaction system comprises a physical data module, a virtual-real interaction module and a virtual data module; the test bench is arranged on a horizontal ground and comprises a coal cutter, various sensors, an adjusting frame and a supporting frame which are matched with a tested coal cutter controller;
the coal mining machine is different according to the working requirements of the fully mechanized mining face, and is arranged on the support frame through the adjusting frame to perform idle running and mining height adjustment; the adjusting frame consists of a supporting frame, a pitch angle push rod and a roll angle push rod, the pitch angle push rod and the roll angle push rod can adjust the pitch angle and the roll angle of the coal mining machine in real time under the control of virtual coal mining machine data, and the attitude change of the coal mining machine in the operation of an underground actual working environment is simulated; the coal mining machine is additionally provided with a sensor, and the type at least comprises a traction part shaft encoder, a rocker arm inclination angle sensor and strapdown inertial navigation;
the virtual coal seam floor model obtains the rule of the trend change of the corresponding coal seam according to geological detection data and operation data of a real underground experienced coal mining machine driver, and then obtains a coal seam data point according to a similar design method; the bottom plate model is fluctuated, has a certain inclination angle and simulates the inclination state of the top bottom plate of a real underground coal bed. Simulating the inclination state of the top floor and the bottom floor of a real underground coal seam by using the floor model; the virtual coal mining machine and the virtual scraper conveyor are constructed based on the geometric overall dimensions of the coal mining machine to be tested and the scraper conveyor matched with the coal mining machine;
the scene display comprises a coal cutter cutting curve generation panel and a data display panel; the cutting curve generation panel of the coal mining machine is used for drawing a cutting track of a drum of the coal mining machine by using a LineRender component in a virtual test scene, displaying a cutting curve in real time in the running process of the virtual coal mining machine and realizing the visualization of the whole coal cutting process; the data display panel is a GUI system in Unity, and links and displays the running speed of the virtual coal mining machine, the angles of the left rocker arm and the right rocker arm, the heights of the left roller and the right roller, the pitch angle of the machine body and the roll angle with the variable of the sensor by compiling script codes, so that the real-time display and monitoring of the pose information of the coal mining machine to be tested are realized;
the physical data module is used for receiving real-time machine body inclination angle information of the coal mining machine in the virtual-real interaction module, controlling the movement of a pitch angle push rod and a roll angle push rod of an adjusting frame of the test bench, and simulating the working posture change of the coal mining machine in the underground real environment in real time; the virtual-real interaction module is used for carrying out data interaction with the physical data module and the virtual data module, real-time data and control instructions are transmitted between the physical data module and the virtual data module through the virtual-real interaction module, the real-time data are sent to the virtual data module, and the virtual coal mining machine is driven to act and display; the virtual data module is used for receiving the real-time pose and the running speed of the coal mining machine to be tested, transmitting the pose and the running speed to a virtual test scene, and driving the virtual coal mining machine to act and display the pose and the running speed in real time.
Adding rigid body and collision body components on the virtual coal seam floor model to simulate the supporting effect of a real coal seam floor on a scraper conveyor; the method comprises the following steps that 1:1 modeling is carried out on a virtual coal cutter and a virtual scraper conveyor in UG software according to the model and the geometric overall dimension of an actual tested model, the model is led into 3D MAX software after modeling is completed, the model format is converted into Fbx format, finally, models in Fbx format of each part of the coal cutter and the scraper conveyor are led into Unity3D, and the construction of the coal cutter and the scraper conveyor in a virtual test scene is completed;
compiling C # scripts to realize the control of the walking, acceleration and deceleration, the lifting of the left rocker arm and the right rocker arm and the rotation of the roller of the virtual coal mining machine according to the test requirements; adding a control script for the virtual scraper conveyor to enable the virtual scraper conveyor to be paved on a coal seam bottom plate with high and low fluctuation in a self-adaptive manner;
according to the test requirement, writing a C # program for the virtual coal mining machine, reserving attitude driving variables of a pitch angle and a roll angle, and associating the attitude driving variables with the real-time position and the attitude data volume of the actual coal mining machine to be tested through a virtual-real interaction system; the method specifically comprises the following steps: during testing, acquiring real-time pose data of the coal mining machine to be tested through a sensor arranged on the coal mining machine to be tested, transmitting the real-time pose data to a virtual data module through a virtual-real interaction module, processing the real-time pose data of the coal mining machine to assign a posture driving variable corresponding to the virtual coal mining machine, and driving the virtual coal mining machine to synchronously perform position posture actions;
rigid body and collision body components are added in a virtual coal mining machine and a virtual scraper conveyor to simulate the interaction of a real coal mining machine with a coal bed and the scraper conveyor, so that the virtual scraper conveyor can be flatly paved on a coal bed bottom plate with high and low fluctuation in a self-adaption mode, a sliding shoe of the virtual coal mining machine is arranged on a chute coal shoveling plate of the virtual scraper conveyor, and a machine body is parallel to the scraper conveyor.
The physical data module receives real-time pose and running speed data of a coal mining machine to be tested, which are acquired by a sensor mounted on the coal mining machine, and sends the real-time pose and running speed data to the virtual-real interaction module, and the virtual-real interaction module sends the real-time data to the virtual data module to drive the virtual coal mining machine to act and display; meanwhile, the physical data module receives real-time machine body inclination angle information of the coal mining machine in the virtual-real interaction module, controls the movement of a pitch angle push rod and a roll angle push rod of an adjusting frame of the test bench, and simulates the posture change of the coal mining machine working in the underground real environment in real time;
the virtual data module is communicated with the virtual-real interaction module and the virtual test scene and exchanges information with the virtual-real interaction module and the virtual test scene; a sensor installed on the coal mining machine collects real-time pose and running speed data of the coal mining machine to be tested and transmits the data to a physical data module, the physical data module transmits the real-time data to a virtual data module through a virtual-real interaction module, and the virtual data module transmits the real-time pose and running speed data of the coal mining machine to be tested to a virtual test scene after receiving the real-time pose and running speed data of the coal mining machine to be tested, and drives the virtual coal mining machine to act and display the data in real time.
Corresponding sensors are arranged at key positions of the coal mining machine, and the installation positions are shown in figure 3. The traction part shaft encoder is used for measuring the rotating speed of a traction motor of the coal mining machine and calculating the speed of the coal mining machine; the rocker arm inclination angle sensor is used for measuring the angles of the left rocker arm and the right rocker arm and calculating mining height data of the roller; the strapdown inertial navigation is used for measuring a pitch angle, a roll angle and a real-time space three-dimensional coordinate of a body of the coal mining machine.
As shown in fig. 4, the invention provides a virtual-real fused coal mining machine memory cutting test method, which performs a test by using the virtual-real fused coal mining machine memory cutting test system according to the technical scheme, and comprises the following steps:
step 1: constructing a virtual test scene; acquiring operation data and geological detection data of a driver of the underground coal mining machine according to the coal seam where the coal mining machine to be tested is located, and establishing a virtual coal seam floor model; constructing a virtual coal cutter and a virtual scraper conveyor, carrying out 1:1 modeling in UG software according to the models and the geometric overall dimensions of the actual coal cutter and the scraper conveyor, importing the models into 3D MAX software after the modeling is finished, converting the model formats into Fbx formats, importing all parts Fbx format models into Unity3D, and finishing the construction of equipment models in a virtual test scene;
and acquiring geological detection data such as drilling data, actual measurement data and the like of the coal seam where the coal mining machine to be tested is located, and combining operation data of a real underground experienced coal mining machine driver to obtain a preliminary coal seam data point. And performing Kriging interpolation processing on the obtained coal seam data points to obtain a large number of data points required by the coal seam floor model, performing Delaunay triangulation on the interpolated data, establishing a TIN (triangulated irregular network) by using a C # script in Unity3D, rendering, and establishing a virtual coal seam floor model.
After the virtual test scene is built, a coal mining machine and a scraper conveyor script assembly are respectively created and added to control the movement of an object, and a C # script is compiled according to the test requirement to realize the control of the walking, acceleration and deceleration, the lifting of a left rocker arm and a right rocker arm and the rotation of a roller of the virtual coal mining machine;
rigid body and collision body components are added at key parts of a virtual coal mining machine and a virtual scraper conveyor, and the interaction between a real coal mining machine and a coal bed and the scraper conveyor is simulated, so that the virtual scraper conveyor can be flatly laid on a coal bed bottom plate with high and low fluctuation in a self-adaptive manner, a sliding shoe of the virtual coal mining machine can be laid on a chute coal shoveling plate of the virtual scraper conveyor, and a machine body is parallel to the scraper conveyor;
according to the test requirement, writing a C # program for the virtual coal mining machine, reserving pitch angle and roll angle attitude driving variables, and associating the attitude variables with the real-time position and attitude data volume of the coal mining machine to be tested through a virtual-real interaction system; during testing, the sensor acquires real-time pose data of a coal mining machine to be tested, the real-time data is transmitted to the virtual data module through the physical data module by the virtual-real interaction module, the virtual data module processes the real-time pose data of the coal mining machine to assign attitude driving variables corresponding to the virtual coal mining machine, and the virtual coal mining machine is driven to synchronously perform position and attitude actions;
in the OnGUI method, a data display panel is created by writing character strings, the running speed of a virtual coal mining machine, the angles of a left rocker arm and a right rocker arm, the heights of a left roller and a right roller, the pitch angle of a machine body and the roll angle are linked with sensor variables and displayed, and the real-time display and monitoring of the pose information of the coal mining machine are realized;
the modules established by the virtual coal mining machine comprise a machine body, a rocker arm, a roller, a traction part, a heightening oil cylinder, a guide sliding shoe and the like, and the modules simplify a motor, a reduction gearbox, a hydraulic unit and the like in the machine body. The virtual scraper conveyor mainly shows that the virtual scraper conveyor is paved on a rugged virtual coal bed in a self-adaptive mode and has a supporting effect on a virtual coal mining machine, and a coal conveying scene is not shown, so that a machine head, a machine tail and a middle groove are mainly established, and a scraper chain is simplified.
In order to ensure the accuracy of single-machine movement of the virtual coal mining machine, the model is repaired before being introduced, the movement between the coal mining machine components can be decomposed into translation and rotation, the rotation points connected between the components are generally connected through pin shafts, so that the model is repaired, and the pin shafts are added at key points of relative movement. The specific addition of the pin shaft is as follows: the coal mining machine is added with a left (right) rocker arm pin shaft, a left (right) roller pin shaft, a left (right) heightening oil cylinder pin shaft and a left (right) piston pin shaft. And a connecting pin shaft is added on the middle grooves of two adjacent sections of the scraper conveyor.
The model built in UG is exported to stl format which can not be identified by Unity3D software, 3D Max software is selected to convert the format into FBX format of intermediate format, the file is exported to project resource folder, Unity can refresh the resource immediately, and the change is applied to the whole project. In the conversion process, the relative position of the three-dimensional model is ensured to be unchanged, and the parts with relative motion relation can still normally move in the virtual software.
The Unity3D can conveniently establish a parent-child relationship in a Hierarchy view, and the parent-child relationship is established by analyzing the motion condition of the coal mining machine. The relative influence relationship of the movement of the parts of the coal mining machine is as follows: the machine body moves left and right, and all parts on the coal mining machine move along with the machine body; the rocker arm rotates around the rocker arm pin shaft to realize ascending and descending, and the corresponding roller ascends and descends along with the rocker arm; the heightening oil cylinder and the rocker arm move cooperatively, the heightening oil cylinder rotates around the heightening oil cylinder pin shaft, the piston rotates along with the heightening oil cylinder pin shaft, and meanwhile, the piston moves linearly relative to the heightening oil cylinder.
The scraper conveyor is formed by connecting a large number of middle grooves, and in order to conveniently and simply build a virtual scene, a preset body is created for the group objects, the preset body is directly called for many times, and then the position of the preset body is placed.
And placing the position of the example object in the virtual scene according to the actual production condition of the fully mechanized mining face. The Unity can select a coordinate system according to the self requirement, choose to place 'three machines' in a world coordinate system, and the Transform component in the observer view of each example object contains information such as position coordinates, rotation, scaling and the like, so that the object can be conveniently placed.
The method comprises the steps of building a virtual test scene, respectively creating and adding a coal mining machine and a scraper conveyor script assembly to control the movement of an object, and compiling a C # script to realize the control of the actions of the virtual coal mining machine, such as walking, acceleration and deceleration, lifting of a left rocker arm and a right rocker arm, rotation of a roller and the like according to test requirements.
Rigid body and collision body components are added at key parts of the virtual coal mining machine and the virtual scraper conveyor to simulate the interaction of a real coal mining machine with a coal bed and the scraper conveyor, so that the virtual scraper conveyor can be flatly laid on a coal bed bottom plate with high and low fluctuation in a self-adaptive manner, a sliding shoe of the virtual coal mining machine can be laid on a chute coal shoveling plate of the virtual scraper conveyor, and a machine body is parallel to the scraper conveyor.
And according to the test requirement, writing a C # program for the virtual coal mining machine, reserving attitude driving variables such as a pitch angle, a roll angle and the like, and associating the attitude driving variables with the real-time position and the attitude data volume of the coal mining machine to be tested through a virtual-real interaction system. The real-time pose data of the coal mining machine to be tested are acquired by each sensor during testing, the real-time data are transmitted to the virtual data module through the virtual-real interaction module through the physical data module, the virtual data module processes the real-time pose data of the coal mining machine to assign values to the corresponding pose driving variables of the virtual coal mining machine, and the virtual coal mining machine is driven to synchronously perform position and pose actions.
Unity has built in a complete set of GUI systems that provide a full set of GUI solutions from layout, controls to skin. The GUI interface is manufactured by using GUI classes and writing script codes.
In the OnGUI method, the running speed of the virtual coal mining machine, the angles of the left and right rocker arms, the heights of the left and right rollers, the pitch angle of the machine body and the roll angle are linked with the variable of the sensor and displayed through character string writing, so that the real-time display and monitoring of the pose information of the coal mining machine to be tested are realized.
Step 2: installing a test bench; selecting coal mining machines of corresponding models according to requirements of a coal mining machine operated on a test fully mechanized mining face and a coal mining machine controller to be tested, and installing the coal mining machines on an adjusting frame on a test bench which is arranged on a horizontal ground;
the coal mining machine is erected by the adjusting frame, idles on the rack and adjusts the mining height, and corresponding sensors are arranged on key positions of the coal mining machine; a shaft encoder is arranged on a motor shaft of a traction part of the coal mining machine and is used for measuring the rotating speed of the traction motor of the coal mining machine; the middle parts of the left rocker arm and the right rocker arm are provided with tilt sensors for measuring the angles of the left rocker arm and the right rocker arm; the method comprises the following steps that a strapdown inertial navigation system is installed on the upper portion of a coal mining machine body and used for measuring a pitch angle, a roll angle and a real-time space three-dimensional coordinate of the coal mining machine body; meanwhile, a controller to be tested is installed on the coal mining machine;
and step 3: starting the test; collecting ten-tool data sets in the actual underground production process, and performing demonstration tool training on a coal mining machine controller according to the first five-tool data of the data sets; operating a traction motor of the coal mining machine according to the data set and adjusting the mining height of the left rocker arm and the right rocker arm, transmitting signals of a sensor on the coal mining machine to a virtual test scene through a virtual-real interaction channel, and driving the virtual coal mining machine to operate on a virtual coal seam bottom plate; the method comprises the steps that the operation state of a virtual coal mining machine is displayed in real time and a cutting curve is displayed on the picture in a virtual test scene, meanwhile, inclination angle change information generated by the virtual coal mining machine operating on a virtual coal seam bottom plate is transmitted to a test table adjusting frame through a virtual-real interaction system, a pitch angle push rod and a roll angle push rod are controlled to move, and the posture change of the coal mining machine working in a real underground environment is simulated in real time; the data display panel displays the position, the speed, the left and right rocker arm angles, the left and right roller heights, the pitch angle of the machine body and the roll angle information of the current virtual coal mining machine in real time for workers to operate and refer to;
the coal mining machine controller autonomously predicts and generates data of the next knife based on the data of the demonstration knife, generates data of the sixth knife according to the data of the first five knives operated by workers, generates data of the seventh knife according to the data of the second knife and the sixth knife, and completes the prediction of the data of the fifth knife by analogy; the method comprises the steps that a coal mining machine controller obtains position information of a virtual coal mining machine in an autonomous prediction process, prediction cutter data drive the virtual coal mining machine to run in a virtual test scene, the virtual test scene displays a cutting curve, a data display panel displays real-time pose information, meanwhile, an actual coal mining machine is driven to run on a test bench, and the effect of cutting is displayed and memorized;
and 4, step 4: the test is finished; and exporting the five-cutter data automatically predicted by the coal mining machine controller through the Unity software, and comparing the data set of the predicted cutter with the data set of the next five cutters actually operated by underground workers through MATLAB software to obtain the effect analysis of the memory cutting of the coal mining machine controller.
The above embodiments are only preferred embodiments of the present invention, and those skilled in the art can make variations and modifications to the above embodiments, therefore, the present invention is not limited to the above embodiments, and any obvious improvements, substitutions or modifications made by those skilled in the art based on the present invention are within the protection scope of the present invention.
Claims (5)
1. A virtual-real fused coal mining machine memory cutting test system is characterized by comprising a virtual test scene, a virtual-real interaction system and a test bench;
the virtual test scene is constructed according to different underground environments applied by actual coal mining machines to be tested and comprises a virtual coal seam bottom plate, virtual equipment and a scene display device, wherein the virtual equipment comprises a virtual scraper conveyor and a virtual coal mining machine; the virtual-real interaction system comprises a physical data module, a virtual-real interaction module and a virtual data module; the test bench is arranged on a horizontal ground and comprises a coal cutter, various sensors, an adjusting frame and a supporting frame which are matched with a tested coal cutter controller;
the coal mining machine is arranged on the support frame through the adjusting frame to perform idle running and mining height adjustment; the adjusting frame consists of a supporting frame, a pitch angle push rod and a roll angle push rod, and the pitch angle push rod and the roll angle push rod can adjust the pitch angle and the roll angle of the coal mining machine in real time under the control of virtual coal mining machine data to simulate the posture change of the coal mining machine in the operation of underground actual working environment; the coal mining machine is additionally provided with a sensor, and the type at least comprises a traction part shaft encoder, a rocker arm inclination angle sensor and strapdown inertial navigation;
the virtual coal seam floor model obtains the law of corresponding coal seam trend change based on geological detection data and operation data of a real underground experienced coal mining machine driver, and obtains coal seam data points according to a similar design method; simulating the inclination state of the top floor and the bottom floor of a real underground coal seam by using the floor model; the virtual coal mining machine and the virtual scraper conveyor are constructed based on the geometric overall dimensions of the coal mining machine to be tested and the scraper conveyor matched with the coal mining machine;
the scene display comprises a coal cutter cutting curve generation panel and a data display panel; the cutting curve generating panel of the coal mining machine is used for drawing a cutting track of a drum of the coal mining machine, displaying the cutting curve in real time in the operation process of the virtual coal mining machine and realizing the visualization of the whole coal cutting process; the data display panel is used for linking and displaying the running speed of the virtual coal mining machine, the angles of the left rocker arm and the right rocker arm, the heights of the left roller and the right roller, the pitch angle of the machine body and the roll angle with the variable of the sensor, so that the pose information of the coal mining machine to be tested is displayed and monitored in real time;
the physical data module is used for receiving real-time machine body inclination angle information of the coal mining machine in the virtual-real interaction module, controlling the movement of a pitch angle push rod and a roll angle push rod of an adjusting frame of the test bench, and simulating the posture change of the coal mining machine in the underground real environment in real time; the virtual-real interaction module is used for carrying out data interaction with the physical data module and the virtual data module, real-time data and control instructions are transmitted between the physical data module and the virtual data module through the virtual-real interaction module, the real-time data are sent to the virtual data module, and the virtual coal mining machine is driven to act and display; the virtual data module is used for receiving the real-time pose and the running speed of the coal mining machine to be tested, transmitting the pose and the running speed to a virtual test scene, and driving the virtual coal mining machine to act and display the pose and the running speed in real time.
2. The virtual-real fused memory cutting test system for the coal mining machine according to claim 1, wherein rigid body and collision body components are added on the virtual coal seam floor model to simulate the supporting effect of a real coal seam floor on a scraper conveyor; the method comprises the following steps that 1:1 modeling is carried out on a virtual coal cutter and a virtual scraper conveyor in UG software according to the model and the geometric overall dimension of an actual tested model, the model is led into 3D MAX software after modeling is completed, the model format is converted into Fbx format, finally, models in Fbx format of each part of the coal cutter and the scraper conveyor are led into Unity3D, and the construction of the coal cutter and the scraper conveyor in a virtual test scene is completed;
compiling C # scripts to realize the control of the walking, acceleration and deceleration, the lifting of the left rocker arm and the right rocker arm and the rotation of the roller of the virtual coal mining machine according to the test requirements; adding a control script for the virtual scraper conveyor to enable the virtual scraper conveyor to be paved on a coal seam bottom plate with high and low fluctuation in a self-adaptive manner;
according to the test requirement, writing a C # program for the virtual coal mining machine, reserving attitude driving variables of a pitch angle and a roll angle, and associating the attitude driving variables with the real-time position and the attitude data volume of the actual coal mining machine to be tested through a virtual-real interaction system; the method comprises the following specific steps: during testing, acquiring real-time pose data of the coal mining machine to be tested through a sensor arranged on the coal mining machine to be tested, transmitting the real-time pose data to a virtual data module through a virtual-real interaction module, processing the real-time pose data of the coal mining machine to assign a posture driving variable corresponding to the virtual coal mining machine, and driving the virtual coal mining machine to synchronously perform position posture actions;
rigid body and collision body components are added in a virtual coal mining machine and a virtual scraper conveyor to simulate the interaction of a real coal mining machine with a coal bed and the scraper conveyor, so that the virtual scraper conveyor can be flatly paved on a coal bed bottom plate with high and low fluctuation in a self-adaption mode, a sliding shoe of the virtual coal mining machine is arranged on a chute coal shoveling plate of the virtual scraper conveyor, and a machine body is parallel to the scraper conveyor.
3. The virtual-real fusion coal mining machine memory cutting test system according to claim 1, wherein the physical data module receives real-time pose and running speed data of a coal mining machine to be tested, which are acquired by a sensor mounted on the coal mining machine, and sends the real-time pose and running speed data to the virtual-real interaction module, and the virtual-real interaction module sends the real-time data to the virtual data module to drive the virtual coal mining machine to act and display; meanwhile, the physical data module receives real-time machine body inclination angle information of the coal mining machine in the virtual-real interaction module, controls the movement of a pitch angle push rod and a roll angle push rod of an adjusting frame of the test bench, and simulates the working posture change of the coal mining machine in the underground real environment in real time;
the virtual data module is communicated with the virtual-real interaction module and the virtual test scene and exchanges information with the virtual-real interaction module and the virtual test scene; a sensor installed on the coal mining machine collects real-time pose and running speed data of the coal mining machine to be tested and transmits the data to a physical data module, the physical data module transmits the real-time data to a virtual data module through a virtual-real interaction module, and the virtual data module transmits the real-time pose and running speed data of the coal mining machine to a virtual test scene after receiving the real-time pose and running speed data of the coal mining machine to be tested, and drives the virtual coal mining machine to act and display the data in real time.
4. The virtual-real fusion shearer memory cutting test system according to claim 1, wherein the traction part shaft encoder is used for measuring the rotation speed of a traction motor of the shearer and calculating the speed of the shearer; the rocker arm inclination angle sensor is used for measuring the angles of the left rocker arm and the right rocker arm and calculating mining height data of the roller; the strapdown inertial navigation is used for measuring a pitch angle, a roll angle and a real-time space three-dimensional coordinate of a machine body of the coal mining machine.
5. A virtual-real fused coal mining machine memory cutting test method, which is used for testing by using the virtual-real fused coal mining machine memory cutting test system according to any one of claims 1-4, and is characterized by comprising the following steps:
step 1: constructing a virtual test scene; acquiring operation data and geological detection data of a driver of the underground coal mining machine according to the coal seam where the coal mining machine to be tested is located, and establishing a virtual coal seam floor model; constructing a virtual coal cutter and a virtual scraper conveyor, carrying out 1:1 modeling in UG software according to the models and the geometric overall dimensions of the actual coal cutter and the scraper conveyor, importing the models into 3D MAX software after the modeling is finished, converting the model formats into Fbx formats, importing all parts Fbx format models into Unity3D, and finishing the construction of equipment models in a virtual test scene;
after the virtual test scene is built, a coal mining machine and a scraper conveyor script assembly are respectively created and added to control the movement of an object, and a C # script is compiled according to the test requirement to realize the control of the walking, acceleration and deceleration, the lifting of a left rocker arm and a right rocker arm and the rotation of a roller of the virtual coal mining machine;
rigid body and collision body components are added at key parts of a virtual coal mining machine and a virtual scraper conveyor, interaction between a real coal mining machine and a coal seam and interaction between the real coal mining machine and the scraper conveyor are simulated, the virtual scraper conveyor can be flatly laid on a coal seam bottom plate with high and low fluctuation in a self-adaptive manner, sliding shoes of the virtual coal mining machine can be laid on a chute coal shoveling plate of the virtual scraper conveyor, and a machine body is parallel to the scraper conveyor;
according to the test requirement, writing a C # program for the virtual coal mining machine, reserving pitch angle and roll angle attitude driving variables, and associating the attitude variables with the real-time position and attitude data volume of the coal mining machine to be tested through a virtual-real interaction system; during testing, the sensor acquires real-time pose data of a coal mining machine to be tested, the real-time data is transmitted to the virtual data module through the physical data module by the virtual-real interaction module, the virtual data module processes the real-time pose data of the coal mining machine to assign attitude driving variables corresponding to the virtual coal mining machine, and the virtual coal mining machine is driven to synchronously perform position and attitude actions;
in the OnGUI method, a data display panel is created by writing character strings, the running speed of a virtual coal mining machine, the angles of a left rocker arm and a right rocker arm, the heights of a left roller and a right roller, the pitch angle of a machine body and the roll angle are linked with sensor variables and displayed, and the real-time display and monitoring of the pose information of the coal mining machine are realized;
step 2: installing a test bench; selecting coal mining machines of corresponding models according to requirements of a coal mining machine operated on a test fully mechanized mining face and a coal mining machine controller to be tested, and installing the coal mining machines on an adjusting frame on a test bench which is arranged on a horizontal ground;
the coal mining machine is erected by the adjusting frame, idles on the rack and adjusts the mining height, and corresponding sensors are arranged on key positions of the coal mining machine; a shaft encoder is arranged on a motor shaft of a traction part of the coal mining machine and is used for measuring the rotating speed of the traction motor of the coal mining machine; the middle parts of the left rocker arm and the right rocker arm are provided with tilt sensors for measuring the angles of the left rocker arm and the right rocker arm; the method comprises the following steps that a strapdown inertial navigation system is installed on the upper portion of a coal mining machine body and used for measuring a pitch angle, a roll angle and a real-time space three-dimensional coordinate of the coal mining machine body; meanwhile, a controller to be tested is installed on the coal mining machine;
and step 3: starting the test; acquiring a ten-tool data set in the actual underground production process, and performing demonstration tool training on a coal mining machine controller according to the first five-tool data of the data set; operating a traction motor of the coal mining machine to operate and adjusting mining heights of a left rocker arm and a right rocker arm according to the data set, transmitting signals of sensors on the coal mining machine into a virtual test scene through a virtual-real interaction channel, and driving the virtual coal mining machine to operate on a virtual coal seam bottom plate; the method comprises the steps that the operation state of a virtual coal mining machine is displayed in real time and a cutting curve is displayed on the picture in a virtual test scene, meanwhile, inclination angle change information generated by the virtual coal mining machine operating on a virtual coal seam bottom plate is transmitted to a test table adjusting frame through a virtual-real interaction system, a pitch angle push rod and a roll angle push rod are controlled to move, and the posture change of the coal mining machine working in a real underground environment is simulated in real time; the data display panel displays the position, the speed, the left and right rocker arm angles, the left and right roller heights, the pitch angle of the machine body and the roll angle information of the current virtual coal mining machine in real time for workers to operate and refer;
the coal mining machine controller autonomously predicts and generates data of the next knife based on the data of the demonstration knife, generates data of the sixth knife according to the data of the first five knives operated by workers, generates data of the seventh knife according to the data of the second knife and the sixth knife, and completes the prediction of the data of the fifth knife by analogy; the coal mining machine controller obtains position information of the virtual coal mining machine in the autonomous prediction process, the virtual coal mining machine is driven to run in a virtual test scene by the aid of predicted cutter data, a cutting curve is displayed in the virtual test scene, real-time pose information is displayed on a data display panel, meanwhile, an actual coal mining machine is driven to run on a test bench, and a cutting effect is memorized;
and 4, step 4: the test is finished; and exporting the five-cutter data automatically predicted by the coal mining machine controller through the Unity software, and comparing the data set of the predicted cutter with the data set of the next five cutters actually operated by underground workers through MATLAB software to obtain the effect analysis of the memory cutting of the coal mining machine controller.
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