CN115906336A - Coal mining machine digital twin model modeling method and system based on hardware-in-the-loop simulation - Google Patents
Coal mining machine digital twin model modeling method and system based on hardware-in-the-loop simulation Download PDFInfo
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Abstract
The invention relates to a method and a system for modeling a coal mining machine digital twin model based on hardware-in-the-loop simulation. The method comprises the following steps: the coal mining machine electric control system receives the control command and decomposes the control command into an actuator action command corresponding to the coal mining machine actuating mechanism; inputting an actuator action instruction into a coal mining machine executing mechanism model and simulating to obtain a virtual sensing and protecting signal; outputting the signal as a digital sensor response to a model order reduction and display system; decoupling the signals through a signal decomposer and displaying data into a conventional data visualization model, a stress visualization model and a motion visualization model; and the visual models are fused into a comprehensive visual digital twin model. The method is based on the digital twin technology, the state data of the coal mining machine is input into the twin model, the working process of the coal mining machine is visualized visually through model regeneration, the health state of the coal mining machine can be reflected through the virtual sensor, and the remote comprehensive visualization control of the coal mining machine is realized.
Description
Technical Field
The invention relates to the technical field of coal mining; specifically, the invention relates to a modeling method and a system of a coal mining machine digital twin model based on hardware-in-the-loop simulation.
Background
At the present stage, the situation of coal mine safety production is still severe and complex, and the research and development of automatic, digital and intelligent technical equipment of a coal mine must be enhanced, so that the safety guarantee capability of the coal mine is improved. The reliability of the coal mining machine, which is used as a main mechanical device for safe and efficient production of a modern mine, directly influences the normal work of the whole coal mining face, and particularly on an automatic working face, the reliable and safe work of the equipment is a key index for ensuring the staff reduction and the efficiency improvement of the working face.
The automation level of the coal mining machine is a key factor influencing the automation level of the fully mechanized coal mining face, and particularly for the application occasions of the coal mining face with severe working conditions and complex environment, the remote automatic coal mining face has the problems of unclear vision and high difficulty in equipment operation and maintenance.
Disclosure of Invention
Accordingly, the present invention is directed to a method and system for modeling a coal mining machine digital twin model based on hardware-in-the-loop simulation that solves or at least alleviates one or more of the above problems and other problems with the prior art.
In order to achieve the foregoing object, a first aspect of the present invention provides a comprehensive visualization modeling method for a coal mining machine digital twin model based on a hardware-in-the-loop simulation technology, wherein the method includes the following steps:
step I: the coal mining machine electric control system receives a coal mining machine control instruction input by a control instruction input module of the coal mining machine, and decomposes the coal mining machine control instruction into an actuator action instruction corresponding to a coal mining machine actuating mechanism through a control instruction decomposition module;
step II: inputting the actuator action instruction into a coal mining machine executing mechanism model, and simulating through a rocker arm model and a traction model in the coal mining machine executing mechanism motion model of the coal mining machine executing mechanism model to obtain a virtual sensing and protecting signal;
step III: outputting the virtual sensing and protection signal as a digital sensor response to a model order reduction and display system;
step IV: in the model order reduction and display system, decoupling the virtual sensing and protection signals through a signal decomposer, displaying the decoupled coal mining machine threshold protection and coal mining machine working state data as a conventional data visualization model, transmitting the decoupled stress data fed back by the coal mining machine actuating mechanism into a stress model, displaying the decoupled stress data as a stress visualization model after mathematical model order reduction processing, and displaying the decoupled attitude data of the coal mining machine actuating mechanism as a motion visualization model; and
step V: and fusing the data in the conventional data visualization model, the stress visualization model and the motion visualization model into a comprehensive visualization digital twin model.
In the method for modeling the coal mining machine digital twin model through comprehensive visualization, optionally, the coal mining machine actuator motion model is a mathematical simulation model, and the method further includes the following steps: and converging the model parameters of the mathematical simulation model according to the difference function of the response signal of the mathematical simulation model and the real response signal of the coal mining machine electric control system, and converging the mathematical simulation model to be consistent with the real motion model of the coal mining machine executing mechanism.
In the method for modeling the coal mining machine digital twin model comprehensive visualization, optionally, the coal mining machine actuator motion model is subjected to model initialization before running, the model initialization is processed by a model variable initialization module, and the convergence process includes the following steps:
the control instruction decomposition module inputs the coal mining machine control instruction and the time sequence into a time sequence parameter table in the coal mining machine executing mechanism motion model, the real response signal of the coal mining machine inputs the real-time state data of the coal mining machine into a state parameter table of the coal mining machine executing mechanism motion model, a data reading component in the coal mining machine executing mechanism motion model reads the time sequence parameters and the state parameters in the time sequence parameter table and the state parameter table into the rocker arm model and the traction model for real-time calculation and simulation, the result of the real-time calculation and simulation is output to a parameter conversion and extraction module through a coal mining machine complete machine reduced-order model, the parameter conversion and extraction module carries out initialization parameter self-convergence on the output state variable of the coal mining machine executing mechanism motion model through the rocker arm model and the traction model, and finally the model variable of the coal mining machine executing mechanism motion model in the next period is obtained and is output to the model variable initialization module for storage.
In the comprehensive visualization modeling method for the digital twin model of the coal mining machine as described above, optionally, the method further includes the following steps:
performing virtual measurement of environmental stress and electrical stress through the coal mining machine executing mechanism model, so that the virtual measurement of the environmental stress and the electrical stress has the same early warning and fault protection logic as the real coal mining machine;
and comparing the time sequence of the early warning and fault protection logic of the coal mining machine with the time sequence of the early warning and fault protection logic of the coal mining machine execution mechanism model, and correcting the early warning and fault protection logic of the coal mining machine execution mechanism model in real time.
In the above comprehensive visualization modeling method for a coal mining machine digital twin model, optionally, in the step III, a digital sensor response output module is used for the output, and the digital sensor output module is a software program interface module, and is used for performing data interaction between the virtual sensing and protection signals from the coal mining machine mechanism motion model and the model order reduction and display system.
In the method for modeling the coal mining machine by comprehensive visualization of the digital twin model as described above, optionally, in the step IV, the signal decomposer is decoupled by software, and the decoupling step includes: and decomposing the data packet input with the virtual sensing and protection signal into a data matrix, wherein the data matrix is divided into a conventional data visualization model matrix, a stress model matrix and a motion mechanism model matrix according to the data type.
In the comprehensive visualization modeling method for the digital twin model of the coal mining machine as described above, optionally, the conventional data visualization model matrix includes coal mining machine threshold protection and coal mining machine working state data, and the coal mining machine threshold protection and coal mining machine working state data are transmitted to the conventional data visualization module in a matrix manner and displayed as the conventional data visualization model as a basic monitoring interface;
the stress model matrix is subjected to mathematical model reduction treatment according to stress types, and the stress model matrix after the reduction treatment is displayed as a stress visualization model in a stress visualization mode; and
and the motion mechanism model matrix is used as input information to assign values to the action parameters of the motion model of the coal mining machine mechanism and then directly displayed as a motion visualization model.
In the method for modeling the coal mining machine with the comprehensive visualization of the digital twin model as described above, optionally, the virtual sensing and protection signal includes an electrical signal, a hydraulic signal and a temperature signal.
In order to achieve the above object, a second aspect of the present invention provides a comprehensive visualization modeling system for a digital twin model of a coal mining machine, wherein the comprehensive visualization modeling system for a digital twin model of a coal mining machine performs comprehensive visualization modeling for a digital twin model of a coal mining machine based on the comprehensive visualization modeling method for a digital twin model of a coal mining machine as described in any one of the first aspect.
In the comprehensive visualization modeling system of a coal mining machine digital twin model as described above, optionally, the comprehensive visualization modeling system of a coal mining machine digital twin model includes:
the coal mining machine is provided with a control instruction input module, a coal mining machine electric control system, an actuator control instruction decomposition module and a coal mining machine real response signal output module, wherein the control instruction input module inputs a coal mining machine control instruction to the coal mining machine electric control system, and the coal mining machine electric control system decomposes the coal mining machine control instruction into an actuator action instruction corresponding to a coal mining machine executing mechanism through the actuator control instruction decomposition module;
the coal mining machine executing mechanism model comprises a coal mining machine mechanism motion model module, a digital sensor response output module and a display system, wherein the coal mining machine executing mechanism model comprises a rocker arm model module and a traction model module, and the digital sensor response output module is used for outputting virtual sensing and protection signals obtained by the coal mining machine mechanism motion model in an anti-true mode to the model reduction and display system; and
the model order reduction and display system comprises a signal decomposer module and an integrated visual module, wherein the signal decomposer module is used for decoupling the virtual sensing and protection signal, displaying the threshold protection of the coal mining machine and the working state data of the coal mining machine obtained through decoupling as a conventional data visual model, transmitting the stress data fed back by the coal mining machine actuating mechanism obtained through decoupling into a stress model, displaying the stress data as a stress visual model after mathematical model order reduction processing, displaying the posture data of the coal mining machine actuating mechanism obtained through decoupling as a motion visual model, and integrating the data in the conventional data visual model, the stress visual model and the motion visual model into an integrated visual digital twin model.
According to the coal mining machine digital twin model modeling method and the coal mining machine digital twin model comprehensive visual modeling system based on hardware-in-the-loop simulation, the state data in the running process of the coal mining machine is input into the twin model based on the digital twin technology, the working process of the coal mining machine is visually visualized and transparent through model regeneration, the health state of the coal mining machine can be reflected through a virtual sensor in the model, and the remote comprehensive visual control of the coal mining machine is realized.
Drawings
The disclosure of the present invention will be more apparent with reference to the accompanying drawings. It is to be understood that these drawings are solely for purposes of illustration and are not intended as a definition of the limits of the invention. In the figure:
FIG. 1 is a schematic block diagram of an embodiment of a coal mining machine digital twin model comprehensive visual modeling system and a flow chart of an embodiment of a modeling method thereof according to the present invention;
FIG. 2 is a schematic block diagram illustrating an initialization of a motion model of an actuator of the shearer loader in the embodiment of FIG. 1;
fig. 3 is a schematic diagram of the decoupling of the signal splitter in the embodiment of fig. 1.
Detailed Description
The composition, features and advantages of the method and system for modeling a digital twin model of a coal mining machine based on hardware-in-the-loop simulation according to the present invention will be described below by way of example with reference to the accompanying drawings and specific embodiments, however, all the descriptions should not be construed as forming any limitation on the scope of the present invention.
Furthermore, any single feature described or implicit in an embodiment or any single feature shown or implicit in the drawings or shown or implicit in the drawings may still allow any combination or permutation to continue between the features (or their equivalents) without any technical impediment, and thus further embodiments according to the invention should be considered within the scope of this disclosure.
Fig. 1 is a schematic block diagram of an embodiment of a coal mining machine digital twin model comprehensive visualization modeling system and a flow chart of an embodiment of a modeling method thereof.
As can be seen from fig. 1, the comprehensive visualization modeling system for the coal mining machine digital twin model may include three systems, namely, a coal mining machine real object system, a coal mining machine executing mechanism model system, and a model order reduction and display system. The coal mining machine digital twinning technology of the modeling method of the visual modeling system can relate to coal mining machine motion mechanisms and stress model digital twinning.
Herein, the shearer loader refers to a shearer loader entity. According to the illustrated example, the shearer may have a control command input module, a shearer electrical control system, an actuator control command decomposition module, and a shearer true response signal output module.
And an operator inputs a coal mining machine control instruction to the coal mining machine electric control system through the control instruction input module. For example, the control command input module may be a remote controller, a body control panel, or the like, or may be a remote operation module, or the like. The instruction may be a manual operation input instruction. For example, when a user operates the "left rocker arm up" function of the coal mining machine, the user can press a "left rocker arm up" command through a remote controller or an electric cabinet panel, and the command enters the coal mining machine execution mechanism motion model through the coal mining machine electric control system in a communication control mode.
The coal cutter electric control system decomposes the coal cutter control instruction into actuator action instructions corresponding to each actuating mechanism of the coal cutter through the actuator control instruction decomposition module. The control commands are usually only one operation at a time, for example, a remote controller, a body panel, a remote operation module, etc., when the shearer performs the corresponding action. In some embodiments, the actuating mechanism may be a ranging arm, drum, tractor, etc. of the shearer, which may be broken down into acceleration, deceleration of the tractor, or lifting of the drum, etc. to be divided into a tractor or ranging arm, at which the drum is located.
For example, when the 'left rocker arm lifting' function of the coal mining machine is executed, the motion model of the coal mining machine executing mechanism identifies whether other control instructions are output at the instruction meaning, the instruction operation time and the corresponding moment, and simulates kinematic state information such as the specific lifting height of the coal mining machine rocker arm, wherein the state information is the response output signal of the digital sensor. The kinematic information such as the height of a rocker arm output by the coal mining machine executing mechanism model and the state information such as the motor current, the oil liquid pressure, the temperature and the like for each executing mechanism output by the coal mining machine in real objects are transmitted to the model order reduction and display system.
The shearer real response signal here refers to the signal of a sensor on the shearer. Various sensors can be arranged on the coal mining machine to detect the operation condition of each actuating mechanism of the coal mining machine, and real response signals of the coal mining machine are generated by a real response signal output module of the coal mining machine and are output to a model of the actuating mechanism of the coal mining machine and a model reduction and display system. At the position of the coal mining machine executing mechanism model, the real response signal of the coal mining machine can be used for converging the coal mining machine executing mechanism motion model so as to correct the alignment error of the coal mining machine executing mechanism motion model and realize the function of closed loop feedback self-identification. At the model order reduction and display system, according to specific requirements, the real response signal of the coal mining machine can be decomposed and reduced by a signal decomposer, and visual output is realized.
As shown in the figure, the shearer loader executing mechanism model comprises a shearer mechanism motion model module and a digital sensor response output module.
The shearer mechanism motion model module may include a rocker arm model module and a traction model module. After the actuator action instruction is input into the coal mining machine mechanism motion model, virtual sensing and protection signals such as electric signals, hydraulic signals, temperature signals and the like are obtained through simulation of a rocker arm model and a traction model in the coal mining machine mechanism motion model, and the virtual sensing and protection signals are used as output signals of a digital sensor response output module and output to a model order reduction and display system.
The motion model of the coal mining machine mechanism can be a mathematical simulation model, has the function of self-convergence according to the real response signal output of the coal mining machine, and can converge the model parameters according to the response signal of the simulation model and the difference function of the real response signal output of the coal mining machine entity, so as to ensure that the mathematical model can be converged to be consistent with the physical model quickly. In an optional embodiment, the convergence of the mathematical simulation model parameters can be realized according to the comparison of the response signals of the mathematical simulation model and the formation of the real response signals of the coal mining machine electrical control system according to the convergence of the difference function.
The model initialization is required before the motion model of the coal mining machine mechanism runs, and the model initialization module is required to process the motion model. As shown in fig. 2. Fig. 2 is a schematic block diagram of initialization of a motion model of an actuating mechanism of the coal mining machine in the embodiment of fig. 1. The specific implementation process of the convergence method comprises the following steps: the instruction decomposition module inputs instructions and time sequence into a time sequence parameter table in the motion model, and the response signal of the coal mining machine inputs real-time state data into a state parameter table of the model; the time sequence parameters and the state parameters are finally read into the rocker arm model and the traction model through a data reading assembly in the model to carry out real-time calculation simulation; and the simulation result is output to a parameter conversion and extraction module through a complete machine order reduction model of the coal mining machine, the module carries out initialization parameter self-convergence on the output state variable of the model through the rocker arm model and the traction model, finally the model variable of the next period is obtained and is output to a model variable initialization module for storage.
In an optional embodiment, the motion model of the coal mining machine mechanism can have an environmental stress and electrical stress virtual measurement function, and the virtual measurement function has the same early warning and fault protection logic as the coal mining machine entity and has a self-correcting function; the self-correcting function compares the early warning and protection time sequence of the physical model with the virtual protection time sequence in the mechanism model, and corrects the early warning and fault protection logic in real time.
For example, if the sensor on the rocker arm fails, the actual height of the rocker arm cannot be known when the rocker arm is operated to move up and down, but the actual height can be raised by an acceleration command, and then the amount of the required raising can be known after the model of the rocker arm is known, for example, the raising amount can be controlled according to the operation duration, so that a digital model can be generated. The coal mining machine can still be reliably operated and monitored under the condition that the sensor fails.
Similarly, if it is inconvenient to install sensors at certain locations of the shearer, it may also be simulated by the digital twin model to visually display the movement and status of those locations, thereby facilitating monitoring and maneuvering.
The digital sensor response output module is used for outputting virtual sensing and protection signals obtained by the coal mining machine mechanism motion model in an anti-true mode to the model order reduction and display system. Thus, in the event of a failure of the shearer's sensors, the shearer may still be manipulated and monitored by the visual model.
In an alternative embodiment, the digital sensor output module may be a software program interface module, such as a software program interface API module, for software-to-software data interaction of the virtual measurement data signals from the shearer mechanism motion model software with the model reduction and display system.
The model order reduction and display system comprises a signal decomposer module and a comprehensive visual module.
The signal decomposer module decouples the virtual sensing and protection signals. Fig. 3 is a schematic diagram of the decoupling of the signal splitter in the embodiment of fig. 1. For example, the signal decomposer may decouple and output the signal into three parts, the signal decomposer is a software decomposer, that is, an input data packet is decomposed into data matrixes, the data matrixes are divided according to data types, the data types are divided into three types, and a conventional data visualization model matrix, a stress model matrix and a motion mechanism model matrix are provided. The conventional data visualization model matrix comprises coal mining machine threshold protection and state data related to coal mining machine work, the data are transmitted to the conventional data visualization module in a matrix mode, and the data are displayed as the conventional data visualization model as a basic monitoring interface. The stress model matrix needs to be subjected to mathematical model reduction treatment according to stress types, and the stress model matrix after the reduction treatment is displayed as a stress visualization model in a stress visualization mode. And the motion mechanism model matrix is used as input information to assign values to each motion parameter of the motion model of the coal mining mechanism and then directly output to the motion visualization model for displaying. And finally, fusing data in the conventional data visualization module, the stress visualization module and the motion visualization module into a digital twinborn comprehensive visualization model, wherein the model has the functions of basic state data display, three-dimensional motion and stress visualization and model self-correction.
After signal decoupling, displaying the threshold protection of the coal mining machine and the working state data of the coal mining machine obtained through decoupling as a conventional data visualization model, transmitting the stress data fed back by the actuating mechanism of the coal mining machine obtained through decoupling into the stress model, performing mathematical model reduction processing, displaying as the stress visualization model, and displaying the attitude data of the actuating mechanism of the coal mining machine obtained through decoupling as the motion visualization model. The model reduction processing can reduce the calculation dimension, reduce the calculation amount and save the calculation time and the CPU load. The comprehensive visual module can fuse the data in the conventional data visualization model, the stress visualization model and the motion visualization model into a comprehensive visual digital twin model.
For example, kinematic information such as the height of a rocker arm output by a coal mining machine actuator model and state information such as motor current, oil pressure and temperature for each actuator output by a coal mining machine in real object are transmitted to the model order reduction and display system. Then, information is transmitted to the model order reduction and display system, and signals are decoupled and output into three parts through the signal decomposer module: all signals generated by the coal mining machine real response signal output module are directly transmitted to the conventional data visualization module for display; the method comprises the steps of obtaining vibration of a rocker arm of the coal mining machine and rocker arm mechanical state characteristic matrix information of subsystems in a rocker arm transmission system through stress model simulation according to kinematic information output by a rocker arm model and load state information such as motor current and the like of each actuating mechanism output by a coal mining machine in a real object, finally obtaining a state information matrix after reduction through model reduction and simplification, and displaying the state information matrix through a stress visual module in a visual mode. And the attitude state data of the coal mining machine executing mechanism is directly output to the visual model through the motion model for displaying. The kinematic information output by the rocker arm model is the final height information of the rocker arm, the information is used for calculating the stroke information, the kinematic state information and the like of each actuating mechanism of the rocker arm through the rocker arm kinematic model, and finally, the information is visually displayed through motion vision. And finally, the data in the conventional data visualization module, the stress visualization module and the motion visualization module are integrated into a comprehensive visualization digital twin model, and the model has the functions of basic state data display, three-dimensional motion and stress visualization and model self-correction.
With reference to the comprehensive visualization modeling system of the coal mining machine digital twin model of fig. 1, the following description continues to describe the comprehensive visualization modeling method of the coal mining machine digital twin model based on the hardware-in-the-loop simulation technology of the present invention. The method may include the following steps I to V.
In the step I, the coal mining machine electric control system receives a coal mining machine control instruction input by a control instruction input module of the coal mining machine, and decomposes the coal mining machine control instruction into an actuator action instruction corresponding to an actuating mechanism of the coal mining machine through a control instruction decomposition module.
As described above, the control command received by the electronic control system of the coal mining machine may be from a remote controller, a body panel, a remote operation module, etc., and may be used to operate the traction device or the rocker arm device. The rocker arm device can be operated and controlled through hydraulic pressure; the traction device can be operated by a motor. The control command can be manually operated by an operator and input into an electric control system of the coal mining machine. The coal mining machine electric control system decomposes the instruction input by the operator into the actuator action instruction corresponding to each actuating mechanism of the coal mining machine.
And the coal cutter electric control system outputs the control instruction of the executing mechanism to the coal cutter executing mechanism after receiving the control instruction. The control instruction of the executing mechanism is decomposed into an actuator action instruction corresponding to the executing mechanism of the coal mining machine in the control instruction decomposition module. In an alternative embodiment, the control instruction decomposition module can be a submodule in the coal cutter electric control system. The actuator motion command may be, for example, a rocker arm control command, a traction control command, or the like.
And II, inputting the actuator action instruction into a coal mining machine executing mechanism model, and simulating through a rocker arm model and a traction model in the coal mining machine executing mechanism motion model of the coal mining machine executing mechanism model to obtain a virtual sensing and protecting signal.
Here, the shearer loader executing mechanism model includes a shearer loader mechanism moving model, which may include a ranging arm model and a haulage model, or may further include other models. These models can simulate the motion of real devices in the shearer. Meanwhile, virtual sensing and protecting signals can be obtained based on the simulation of the rocker arm model and the traction model. In alternative embodiments, the virtual sensing and protection signals may include electrical signals, hydraulic signals, temperature signals, and the like. Virtual sensing and protecting signals such as electric, hydraulic and temperature signals are obtained through simulation of a rocker arm model and a traction model in the coal mining machine mechanism motion model, and can be used as output signals of a digital sensor response output module to be output to a model order reduction and display system.
The motion model of the coal mining machine executing mechanism can be a mathematical simulation model. On the basis, the method further comprises the step of converging the mathematical simulation model, and the mathematical simulation model is self-converged according to the real response signal output of the coal mining machine. Specifically, in this step, the model parameters of the mathematical simulation model are converged according to the difference function of the response signal of the mathematical simulation model and the output of the real response signal of the coal mining machine electrical control system, and the mathematical simulation model is converged to be consistent with the real motion model of the coal mining machine actuating mechanism.
In an alternative embodiment, the movement model of the actuating mechanism of the coal mining machine can have the functions of measuring the environmental stress and the electric stress virtually. The virtual measurement function has the same early warning and fault protection logic as the coal mining machine entity, and has a self-correcting function; regarding the self-correction function, the function compares the early warning and protection timing of the physical model with the virtual protection timing in the mechanism model, and corrects the early warning and fault protection logic in real time.
Specifically, the coal mining machine digital twin model visual modeling method can comprise the following steps of performing virtual measurement on environmental stress and electric stress through the coal mining machine executing mechanism model, so that the virtual measurement on the environmental stress and the electric stress has the same early warning and fault protection logic as that of a real coal mining machine; and comparing the time sequence of the early warning and fault protection logic of the coal mining machine with the time sequence of the early warning and fault protection logic of the coal mining machine execution mechanism model, and correcting the early warning and fault protection logic of the coal mining machine execution mechanism model in real time.
In addition, the coal mining machine executing mechanism motion model can be initialized before running, and the model initialization can be processed through a model variable initialization module. Fig. 2 is a schematic block diagram illustrating initialization of a motion model of an actuator of the shearer loader in the embodiment of fig. 1.
As shown in fig. 2, in an alternative embodiment, the converging process includes the following steps that the control instruction decomposition module inputs the coal mining machine control instruction and time sequence into a time sequence parameter table in the coal mining machine execution mechanism motion model, the real response signal of the coal mining machine inputs real-time state data of the coal mining machine into a state parameter table of the coal mining machine execution mechanism motion model, a data reading component in the coal mining machine execution mechanism motion model reads time sequence parameters and state parameters in the time sequence parameter table and the state parameter table into the rocker arm model and the traction model for real-time computation and simulation, a result of the real-time computation and simulation is output to a parameter conversion and extraction module through a complete machine reduction model, the parameter conversion and extraction module performs initialization parameter self-convergence on output state variables of the coal mining machine execution mechanism motion model through the rocker arm model and the traction model, and finally obtains model variables of the coal mining machine execution mechanism motion model in a next period and outputs the model variables to the model variables initialization module for storage.
In step III, the virtual sensing and protection signals are output to a model order reduction and display system as digital sensor responses.
In an alternative embodiment, a digital sensor response output module is used for the output, and the digital sensor output module may be a software program interface module, and is used for performing data interaction between the virtual sensing and protection signals from the motion model of the coal mining machine mechanism and the model order reduction and display system.
In the step IV, in the model reduction and display system, decoupling the virtual sensing and protection signals through a signal decomposer, displaying the decoupled threshold protection of the coal mining machine and the working state data of the coal mining machine as a conventional data visualization model, transmitting the decoupled stress data fed back by the actuating mechanism of the coal mining machine into the stress model, displaying the stress data as a stress visualization model after mathematical model reduction processing, and displaying the decoupled attitude data of the actuating mechanism of the coal mining machine as a motion visualization model.
In an alternative embodiment, the signal is decoupled and output into three parts by the model reduction and signal decomposer in the display module. The signal decomposer may be a software decoupling, and the decoupling may include decomposing a data packet into which the virtual sensing and protection signal is input into a data matrix, and the data matrix is divided into a conventional data visualization model matrix, a stress model matrix, and a motion mechanism model matrix according to a data type.
The conventional data visualization model matrix can comprise coal mining machine threshold protection and coal mining machine working state data, the coal mining machine threshold protection and coal mining machine working state data are transmitted to the conventional data visualization module in a matrix mode, and are displayed as the conventional data visualization model as a basic monitoring interface. The stress model matrix can be subjected to mathematical model reduction treatment according to stress types, and the stress model matrix after the reduction treatment is displayed as a stress visualization model in a stress visualization mode. The motion mechanism model matrix can be used as input information to assign values to the motion parameters of the motion model of the coal mining machine mechanism and then directly displayed as a motion visualization model.
In step V, data in the conventional data visualization model, the stress visualization model and the motion visualization model are fused into a comprehensive visualization digital twin model. The comprehensive visual digital twin model has the functions of basic state data display, three-dimensional motion and stress visualization and model self-correction.
The method and the system for modeling the digital twin model of the coal mining machine based on hardware-in-the-loop simulation are explained in detail by taking the function of operating the coal mining machine 'left rocker arm to rise' by a user as an example.
Specifically, in this example, the user presses a "left ranging arm up" command via a remote control or an electronic control box panel (i.e., a control command input module), which is entered into the shearer mechanism motion model via the shearer electronic control system in a communication-controlled manner.
The coal mining machine mechanism motion model comprises a rocker arm model and a traction model. The coal mining machine mechanism motion model identifies the instruction meaning, the instruction pressing time and whether other control instructions are output at the corresponding moment, and simulates the kinematic state information such as the specific ascending height of the coal mining machine rocker arm, wherein the state information is the digital sensor response output signal. The kinematic information such as the height of a rocker arm and the like output by the coal mining machine executing mechanism model and the state information such as the motor current, the oil liquid pressure, the temperature and the like for each executing mechanism output by the coal mining machine in real objects are transmitted to the model order reduction and display system.
In the model order reduction and display system, the signal decomposer is used for decoupling and outputting signals into three parts: all signals generated by the coal mining machine real response signal output module are directly transmitted to the conventional data visualization module for display; the method comprises the steps of obtaining vibration of a rocker arm of the coal mining machine and rocker arm mechanical state characteristic matrix information of subsystems in a rocker arm transmission system through simulation of a stress model according to kinematic information output by the rocker arm model and load state information such as motor current and the like of each actuating mechanism output by a coal mining machine in real objects, finally obtaining a state information matrix after reduction through model reduction and simplification, and displaying the state information matrix through a stress visual module in a visual mode. And the attitude state data of the coal mining machine executing mechanism is directly output to the visual model through the motion model for displaying. The kinematic information output by the rocker arm model can include final height information of the rocker arm, and the information can be used for calculating stroke information, kinematic state information and the like of each actuating mechanism of the rocker arm through the rocker arm kinematic model and finally visually displaying through motion vision.
In addition, the output of the coal mining machine true response signal can converge the output actual rising height of the coal mining machine rocker arm on the rocker arm model. The real response signal of the left rocker arm of the electric control system of the coal mining machine output by the real response signal output module of the coal mining machine can include but is not limited to the motion information of the height of the left rocker arm, the action stroke of the left rocker arm and the like, and the information of the motor current, the oil hydraulic pressure and the temperature of the left rocker arm, the vibration of the left rocker arm, the transmission of the left rocker arm and the like.
According to the comprehensive visual modeling method and the comprehensive visual modeling system of the coal mining machine digital twin model based on the hardware-in-the-loop simulation technology, the state data in the running process of the coal mining machine is input into the twin model based on the digital twin technology, the working process of the coal mining machine is visualized and transparentized visually through model regeneration, the health state of the coal mining machine can be reflected through a virtual sensor in the model, the remote comprehensive visual control of the coal mining machine is realized, and the comprehensive visual modeling method and the comprehensive visual modeling system of the coal mining machine digital twin model based on the hardware-in-the-loop simulation technology have the characteristics of convenience in implementation and high reliability.
The technical scope of the present invention is not limited to the contents in the above description, and those skilled in the art can make various changes and modifications to the above embodiments without departing from the technical spirit of the present invention, and these changes and modifications should fall within the scope of the present invention.
Claims (10)
1. A comprehensive visualization modeling method for a coal mining machine digital twin model based on a hardware-in-the-loop simulation technology is characterized by comprising the following steps:
step I: the coal mining machine electric control system receives a coal mining machine control instruction input by a control instruction input module of the coal mining machine, and decomposes the coal mining machine control instruction into an actuator action instruction corresponding to a coal mining machine actuating mechanism through a control instruction decomposition module;
step II: inputting the actuator action command into a coal mining machine executing mechanism model, and simulating through a rocker arm model and a traction model in the coal mining machine executing mechanism motion model of the coal mining machine executing mechanism model to obtain a virtual sensing and protection signal;
step III: outputting the virtual sensing and protection signal as a digital sensor response to a model order reduction and display system;
step IV: in the model order reduction and display system, decoupling the virtual sensing and protection signals through a signal decomposer, displaying the decoupled coal mining machine threshold protection and coal mining machine working state data as a conventional data visualization model, transmitting the decoupled stress data fed back by the coal mining machine actuating mechanism into a stress model, displaying the decoupled stress data as a stress visualization model after mathematical model order reduction processing, and displaying the decoupled attitude data of the coal mining machine actuating mechanism as a motion visualization model; and
step V: and fusing the data in the conventional data visualization model, the stress visualization model and the motion visualization model into a comprehensive visualization digital twin model.
2. The comprehensive visualization modeling method for the digital twin model of the coal mining machine according to claim 1, wherein the motion model of the actuating mechanism of the coal mining machine is a mathematical simulation model, and the method further comprises the following steps: and converging the model parameters of the mathematical simulation model according to the difference function of the response signal of the mathematical simulation model and the real response signal of the coal mining machine electric control system, and converging the mathematical simulation model to be consistent with the real motion model of the coal mining machine executing mechanism.
3. The comprehensive visualization modeling method for the digital twin model of the coal mining machine according to claim 2, characterized in that the coal mining machine actuator motion model is subjected to model initialization before running, the model initialization is processed by a model variable initialization module, and the convergence process comprises the following steps:
the control instruction decomposition module inputs the coal mining machine control instruction and the time sequence into a time sequence parameter table in the coal mining machine executing mechanism motion model, the real response signal of the coal mining machine inputs the real-time state data of the coal mining machine into a state parameter table of the coal mining machine executing mechanism motion model, a data reading component in the coal mining machine executing mechanism motion model reads the time sequence parameters and the state parameters in the time sequence parameter table and the state parameter table into the rocker arm model and the traction model for real-time calculation and simulation, the result of the real-time calculation and simulation is output to a parameter conversion and extraction module through a coal mining machine complete machine reduced-order model, the parameter conversion and extraction module carries out initialization parameter self-convergence on the output state variable of the coal mining machine executing mechanism motion model through the rocker arm model and the traction model, and finally the model variable of the coal mining machine executing mechanism motion model in the next period is obtained and is output to the model variable initialization module for storage.
4. The comprehensive visualization modeling method for the digital twin model of the coal mining machine according to claim 1, characterized by further comprising the steps of:
performing virtual measurement of environmental stress and electrical stress through the coal mining machine executing mechanism model, so that the virtual measurement of the environmental stress and the electrical stress has the same early warning and fault protection logic as the real coal mining machine;
and comparing the time sequence of the early warning and fault protection logic of the coal mining machine with the time sequence of the early warning and fault protection logic of the coal mining machine execution mechanism model, and correcting the early warning and fault protection logic of the coal mining machine execution mechanism model in real time.
5. The comprehensive visualization modeling method for the coal mining machine digital twin model according to claim 1, characterized in that in the step III, the output is performed by a digital sensor response output module, and the digital sensor output module is a software program interface module for performing software-to-software data interaction of the virtual sensing and protection signals from the coal mining machine mechanism motion model and the model order reduction and display system.
6. The comprehensive visualization modeling method for the digital twin model of the coal mining machine according to claim 1, wherein in the step IV, the signal decomposer is decoupled by software, and the decoupling step comprises the following steps: and decomposing the data packet of the input virtual sensing and protection signal into a data matrix, wherein the data matrix is divided into a conventional data visualization model matrix, a stress model matrix and a motion mechanism model matrix according to the data type.
7. The comprehensive visualization modeling method for the digital twin model of the coal mining machine as set forth in claim 6, characterized in that:
the conventional data visualization model matrix comprises coal mining machine threshold protection and coal mining machine working state data, and the coal mining machine threshold protection and coal mining machine working state data are transmitted to the conventional data visualization module in a matrix mode and are displayed as a conventional data visualization model as a basic monitoring interface;
the stress model matrix is subjected to mathematical model reduction treatment according to stress types, and the stress model matrix after the reduction treatment is displayed as a stress visualization model in a stress visualization mode; and
and the motion mechanism model matrix is used as input information to assign values to the motion parameters of the motion model of the coal mining machine mechanism and then directly displayed as a motion visualization model.
8. The comprehensive visual modeling method for the digital twin model of the coal mining machine as claimed in claim 1, characterized in that the virtual sensing and protection signals comprise electrical signals, hydraulic signals and temperature signals.
9. A comprehensive visualization modeling system of a coal mining machine digital twin model, which is characterized by carrying out comprehensive visualization modeling of the coal mining machine digital twin model based on the comprehensive visualization modeling method of the coal mining machine digital twin model according to any one of claims 1 to 8.
10. The comprehensive visualization modeling system for a coal mining machine digital twin model as set forth in claim 9, characterized in that the comprehensive visualization modeling system for a coal mining machine digital twin model comprises:
the coal mining machine is provided with a control instruction input module, a coal mining machine electric control system, an actuator control instruction decomposition module and a coal mining machine real response signal output module, wherein the control instruction input module inputs a coal mining machine control instruction to the coal mining machine electric control system, and the coal mining machine electric control system decomposes the coal mining machine control instruction into an actuator action instruction corresponding to a coal mining machine executing mechanism through the actuator control instruction decomposition module;
the coal mining machine executing mechanism model comprises a coal mining machine mechanism motion model module, a digital sensor response output module and a display system, wherein the coal mining machine executing mechanism model comprises a rocker arm model module and a traction model module, and the digital sensor response output module is used for outputting virtual sensing and protection signals obtained by the coal mining machine mechanism motion model in an anti-true mode to the model reduction and display system; and
the model order reduction and display system comprises a signal decomposer module and an integrated visual module, wherein the signal decomposer module is used for decoupling the virtual sensing and protection signal, displaying the threshold protection of the coal mining machine and the working state data of the coal mining machine obtained through decoupling as a conventional data visual model, transmitting the stress data fed back by the coal mining machine actuating mechanism obtained through decoupling into a stress model, displaying the stress data as a stress visual model after mathematical model order reduction processing, displaying the posture data of the coal mining machine actuating mechanism obtained through decoupling as a motion visual model, and integrating the data in the conventional data visual model, the stress visual model and the motion visual model into an integrated visual digital twin model.
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