WO2023005878A1 - 一种液压支架智能供液系统及工作方法 - Google Patents

一种液压支架智能供液系统及工作方法 Download PDF

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Publication number
WO2023005878A1
WO2023005878A1 PCT/CN2022/107632 CN2022107632W WO2023005878A1 WO 2023005878 A1 WO2023005878 A1 WO 2023005878A1 CN 2022107632 W CN2022107632 W CN 2022107632W WO 2023005878 A1 WO2023005878 A1 WO 2023005878A1
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WIPO (PCT)
Prior art keywords
flow
liquid supply
pressure
hydraulic
pump
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PCT/CN2022/107632
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English (en)
French (fr)
Inventor
赵继云
曹超
王峰
寇子明
苏琦
吴娟
李冉
黄笛
王云飞
于鸣泉
Original Assignee
中国矿业大学
太原理工大学
浙江大学
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Application filed by 中国矿业大学, 太原理工大学, 浙江大学 filed Critical 中国矿业大学
Publication of WO2023005878A1 publication Critical patent/WO2023005878A1/zh

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    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D23/00—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor
    • E21D23/0004—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor along the working face
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D23/00—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor
    • E21D23/006—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor provided with essential hydraulic devices
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D23/00—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor
    • E21D23/006—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor provided with essential hydraulic devices
    • E21D23/0065—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor provided with essential hydraulic devices driven, or automatically, e.g. electrically-hydraulically controlled
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D23/00—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor
    • E21D23/16—Hydraulic or pneumatic features, e.g. circuits, arrangement or adaptation of valves, setting or retracting devices
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D23/00—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor
    • E21D23/16—Hydraulic or pneumatic features, e.g. circuits, arrangement or adaptation of valves, setting or retracting devices
    • E21D23/26—Hydraulic or pneumatic control

Definitions

  • the invention belongs to the field of mining equipment, in particular to an intelligent liquid supply system and working method of a hydraulic support.
  • the hydraulic system of the hydraulic support in the underground working face is composed of a joint liquid supply system composed of multiple pumps, a multi-cylinder working mechanism and a long pipeline. Superimposed on the loss effect of long pipeline power transmission, the continuous flow matching control of the hydraulic support liquid supply system and the actuator has become a difficult problem.
  • the invention provides an intelligent liquid supply system of a hydraulic support and a working method, which can realize the real-time matching of the liquid supply system of the hydraulic support and the liquid demanded by the actuator during the long-distance underground liquid supply process.
  • an intelligent liquid supply system for a hydraulic support comprising:
  • a monitoring and control system which includes a hydraulic support group, a pressure/flow monitoring system and an electro-hydraulic reversing valve group;
  • the hydraulic support group includes several hydraulic supports arranged in parallel, and the hydraulic support includes several actuators;
  • the pressure/flow monitoring system is connected to the hydraulic support group;
  • the plurality of electro-hydraulic reversing valve groups are connected to each actuator of the plurality of hydraulic supports in one-to-one correspondence;
  • An intelligent liquid supply system the intelligent liquid supply system is connected to the pressure/flow monitoring system;
  • the intelligent liquid supply system includes an emulsion tank, an emulsion pump station and a small flow servo pump;
  • the emulsion tank is connected to the emulsion pump station and the small flow servo pump respectively;
  • the emulsion pumping station includes a first large-flow frequency conversion pump and a second large-flow frequency conversion pump;
  • the small flow servo pump, the first large flow frequency conversion pump and the second large flow frequency conversion pump are arranged in parallel and form a loop;
  • One end of the circuit is connected to the liquid inlet of the electro-hydraulic reversing valve group through the liquid supply pipeline;
  • the other end of the circuit is connected with the liquid return pipeline through the liquid return port of the electro-hydraulic reversing valve group.
  • actuators include several columns, push jacks, side push jacks, balance jacks, and side protection jacks, and several of the upright columns, the push jacks, the side push jacks, the balance jacks, and side protection jacks They are respectively arranged in parallel with the electro-hydraulic reversing valve groups, and several digital flow valve groups are arranged between the pushing jack and the electro-hydraulic reversing valves.
  • the pressure/flow monitoring system includes a number of flow meters and a number of pressure sensors, and the two ends of each of the column, the push jack, the side push jack, the balance jack and the side jack are The flow meter and the pressure sensor are provided; the outlets of the small flow servo pump, the first large flow frequency conversion pump, the second large flow frequency conversion pump and several electro-hydraulic reversing valve groups The flow meter and the pressure sensor are arranged at the liquid ports.
  • the small-flow servo pump is controlled by an intelligent liquid supply system; the first large-flow frequency conversion pump and the second large-flow frequency conversion pump supply liquid to the piston cavity of the push jack through the electro-hydraulic reversing valve group .
  • first unloading valve and a second unloading valve
  • the first unloading valve is arranged between the first large-flow frequency conversion pump and the liquid supply pipeline
  • the second unloading valve is arranged in the between the second largest flow variable frequency pump and the liquid supply pipeline.
  • Step S1 data collection: run the liquid supply system, the monitoring control system monitors the small flow servo pump, the emulsion pump station, and the long-distance liquid supply pipeline through several flow meters and pressure sensors The pressure/flow is collected;
  • Step S2 establishing a pressure-flow model: the monitoring and control system analyzes and processes the various data collected in step S1 to establish a pressure-flow model of the liquid supply pipeline;
  • Step S3. Obtain pressure-flow dynamic response: According to the established pressure-flow model, combined with the collected outlet pressure and flow data of the emulsion pump station, study the effect of multi-pump parallel time-sharing and synchronous liquid supply mode on the liquid supply pipe Analyze the impact fluctuation form caused by the pipeline, analyze the pressure transmission, fluctuation frequency and flow change of the liquid supply pipeline, and obtain the pressure-flow dynamic response of the long-distance liquid supply pipeline in real time;
  • Step S4 collecting data under real-time monitoring: real-time monitoring and collecting of the pressure/flow of several actuators;
  • Step S5. Summarize the pressure/flow demand law of the hydraulic system under time-varying load: combine the data collected in step S4 with the pressure-flow dynamic response to summarize the pressure/flow demand of the hydraulic system under time-varying load of several actuators law;
  • Step S6 obtaining pressure/flow characteristics: monitoring the pressure/flow of each hydraulic support or a combination of multiple hydraulic supports under the conditions of lowering, pulling, pushing, lifting and different movement cycles of the hydraulic supports characteristic;
  • Step S7 obtain the dynamic prediction of pressure/flow: combine the pressure/flow characteristics obtained in step S6 with the flow demand law of the hydraulic system under time-varying loads, and dynamically predict the liquid demand of the system under the multi-working mode of several hydraulic supports;
  • Step S8 according to the current specific working conditions, dynamically match with the predicted liquid demand of the system under the multi-working mode of several hydraulic supports, so as to dynamically adjust the first large-flow frequency conversion pump and the second pump in the liquid supply system
  • the liquid supply volume of the two large-flow frequency conversion pumps and the small-flow servo pump matches the liquid demand of the hydraulic support group in real time;
  • the intelligent liquid supply system combines the pressure/flow demand law of the monitoring and control system under time-varying loads to realize multiple hydraulic supports.
  • the system pressure-flow dynamic prediction through the small flow servo pump jointly controlling the emulsion pump station, realizes the liquid supply of the large flow actuator, and realizes the liquid supply loss of the small flow actuator and long-distance liquid supply pipeline Carry out flow and pressure supplement, combined with the monitoring and control system to realize energy-saving and stable pressure intelligent liquid supply under the conditions of multiple actuators and multiple working conditions;
  • the small-flow servo pump when the small-flow servo pump performs liquid supply with small flow, it supplies and replenishes liquid to the large-flow actuators including the columns, and the small-flow actuators include push jacks, side push jacks, balance jacks and side jacks for liquid supply. , to refill the long-distance liquid supply pipeline loss.
  • the invention provides a hydraulic support intelligent liquid supply system and working method.
  • the system can monitor the pressure change of the coal mine underground hydraulic support group in real time, and dynamically predict the actuator according to the hydraulic support periodic work process and the power transmission characteristics of the long pipeline. Real-time adjustment of the liquid supply volume of the multi-pump linkage liquid supply system, realizing the self-adaptive adjustment of system pressure and flow in the multi-working mode of the support group, meeting the intelligent pressure stabilization and energy-saving control requirements of the downhole liquid supply system.
  • Fig. 1 is a structural schematic diagram of an intelligent liquid supply system for a hydraulic support.
  • 1 is the intelligent liquid supply system
  • 2 is the monitoring and control system
  • 3 is the emulsion tank
  • 4 is the small flow servo pump
  • 5 is the frequency conversion pump with the largest flow
  • 6 is the frequency conversion pump with the second largest flow
  • 7 is the flow rate meter, wherein, 7-1 is the first flowmeter, 7-2 is the second flowmeter ... 7-n is the nth flowmeter
  • 8 is the return line
  • 9 is the pressure sensor
  • 9-1 is the first A pressure sensor
  • 9-2 is the second pressure sensor ...
  • a hydraulic support intelligent liquid supply system as shown in Figure 1, this embodiment includes a monitoring control system 2 and an intelligent liquid supply system 1, and the monitoring control system 2 includes a hydraulic support group
  • the pressure/flow monitoring system (corresponding to the pressure-flow monitoring part in the figure)
  • the electro-hydraulic reversing valve group 13 includes multiple groups, here for the convenience of description, They are respectively defined as the first electro-hydraulic directional valve group 13-1, the second electro-hydraulic directional valve group 13-2...the nth electro-hydraulic directional valve group 13-n.
  • the hydraulic support group includes several hydraulic supports 16 arranged in parallel, and the hydraulic support 16 includes several actuators. Some of said actuators include some columns 19, push jacks 22, some side push jacks 14, balance jacks 17, side protection jacks 18, some of said columns 19, said push jacks 22, some of said side push jacks 14, all The balance jack 17 and the side jack 18 are arranged in parallel with the electro-hydraulic reversing valve group 13 respectively, and several digital flow valve groups are arranged between the pushing jack 22 and the electro-hydraulic reversing valve group 13 .
  • the digital flow valve group includes a first digital flow valve 15-1 and a second digital flow valve 15-2, and the first digital flow valve 15-1 and the second digital flow valve 15-2 are respectively arranged in the The two lines connecting the push jack 22 and the first electro-hydraulic reversing valve group 13-1.
  • the pressure/flow monitoring system is connected with the hydraulic support group; the pressure/flow monitoring system includes several flowmeters 7 and several pressure sensors 9, each of the column 19, the moving jack 22, the side pusher The two ends of the jack 14, the balance jack 17 and the support jack 18 are provided with the flow meter 7 and the pressure sensor 9; the small flow servo pump 4, the first large flow variable frequency pump 5 1.
  • the flow meter 7 and the pressure sensor 9 are all set at the outlet of the second large flow frequency conversion pump 6 and the liquid inlets of several electro-hydraulic reversing valve groups 13 .
  • the plurality of electro-hydraulic reversing valve groups 13 are connected to the actuators of the plurality of hydraulic supports 16 in one-to-one correspondence; the intelligent liquid supply system 1 is connected to the pressure/flow monitoring system.
  • the intelligent liquid supply system 1 includes an emulsion tank 3, an emulsion pump station and a small flow servo pump 4, and the small flow servo pump 4 is controlled by the intelligent liquid supply system 1; the first large flow frequency conversion pump 5, The second large-flow frequency conversion pump 6 supplies liquid to the piston cavity of the push jack 22 through the electro-hydraulic reversing valve group 13 .
  • the emulsion tank 3 is connected to the emulsion pump station and the small flow servo pump 4 respectively; the emulsion pump station includes a first large flow frequency conversion pump 5 and a second large flow frequency conversion pump 6;
  • the flow rate servo pump 4, the first large-flow frequency conversion pump 5 and the second large-flow frequency conversion pump 6 are arranged in parallel to form a loop; one end of the loop is connected to several electro-hydraulic reversing valve groups
  • the liquid inlets of 13 are connected respectively; the other end of the circuit is connected with the liquid return pipeline 8 through the liquid return ports of several electro-hydraulic reversing valve groups 13 .
  • This embodiment also includes a first unloading valve 10 and a second unloading valve 11, the first unloading valve 10 is arranged between the first large flow frequency conversion pump 5 and the liquid supply pipeline 12, the second The unloading valve 11 is arranged between the second large flow frequency conversion pump 6 and the liquid supply pipeline 12 .
  • the monitoring and control system 2 controls the multi-pump parallel joint liquid supply to provide the required pressure and flow for the downhole hydraulic system, and the emulsion pump station includes the small flow servo pump 4 and the first large flow frequency conversion through the flow meter 7 and the pressure sensor 9.
  • the pressure/flow of the pump 5, the second largest flow frequency conversion pump 6, and the long-distance liquid supply pipeline 12 are monitored in segments and in real time, and the collected data is analyzed and processed through the control system to initially establish the pressure of the long-distance liquid supply system—
  • the flow model combined with the outlet pressure data of the pumping station, studies the impact fluctuation form of the liquid supply pipeline caused by the multi-pump parallel time-sharing and synchronous liquid supply mode, and analyzes the pressure transmission, fluctuation frequency and flow change of the liquid supply pipeline , obtaining the pressure-flow dynamic response of the long-distance liquid supply pipeline in real time;
  • the intelligent liquid supply system 1 includes a small-flow servo pump 4, a large-flow variable-frequency pump group and an unloading valve group;
  • the large-flow variable-frequency pump group includes a first large-flow variable-frequency pump 5 and a second large-flow variable-frequency pump 6, and the
  • the unloading valve group includes a first unloading valve 10 and a second unloading valve 11;
  • the small flow servo pump 4, the first large flow frequency conversion pump 5, and the second large flow frequency conversion pump 6 are connected in parallel to form a circuit, and one end of the circuit is provided with a liquid supply
  • the pipeline 12 is connected to the liquid inlet of the electro-hydraulic reversing valve group 13 through the liquid supply pipeline 12. It is connected with the liquid return pipeline 8;
  • the first unloading valve 10 is set between the first large flow frequency conversion pump 5 and the liquid supply pipeline 12, and the second unloading valve 11 is set between the second large flow frequency conversion pump 6 and the liquid supply line 12.
  • the intelligent liquid supply system 1 is connected in parallel with a small flow servo pump on the basis of a large flow frequency conversion pump group, and is composed of a small flow servo pump 4, a large flow frequency conversion pump group and an unloading valve group, and a new liquid supply system is established to realize the
  • the flow actuators of the hydraulic support group, the long pipeline liquid supply loss and the flow supplement of the hydraulic system of the support, combined with the monitoring and control system 2, realize the intelligent liquid supply and stable operation of the actuators on the hydraulic supports of the hydraulic support group under multiple working conditions. pressure control.
  • the intelligent liquid supply system 1 and the monitoring and control system 2 further form a closed-loop feedback.
  • the pressure-flow dynamic response of the monitoring and control system 2 is used to intelligently supply the hydraulic system.
  • the monitoring and control system 2 The pressure/flow parameters of the analysis system will be collected again to strengthen the accuracy of the pressure-flow dynamic prediction of the hydraulic system, and combined with the intelligent liquid supply system 1 again to improve the response speed and stability of the intelligent liquid supply system 1 and realize closed-loop feedback optimization, and then obtain the pressure/flow characteristics of each monitoring point, and can predict and control the pressure/flow of the emulsion pump station, and realize the first large flow variable frequency pump 5, the second large flow variable frequency pump 6 and the small flow servo pump 4 and The precise matching of the pressure/flow rate of the actuator improves the quick response and stability of the downhole high-pressure and large-flow liquid supply system.
  • the several flowmeters include a first flowmeter 7-1, a second flowmeter 7-2, a third flowmeter 7-3, a fourth flowmeter 7-4...the nth flowmeter 7- n, the first flow meter 7-1, the second flow meter 7-2, and the third flow meter 7-3 respectively control the small flow servo pump 4, the first large flow frequency conversion pump 5, and the second large flow rate pump.
  • the flow rate at the pump outlet of the flow frequency conversion pump 6 is monitored, and the fourth flowmeter 7-4 monitors the total flow at the pump station outlet.
  • the pressure sensors include a first pressure sensor 9-1 and a second pressure sensor 9-2 , the third pressure sensor 9-3...the nth pressure sensor 9-n, the first pressure sensor 9-1, the second pressure sensor 9-2, and the third pressure sensor 9-3 are respectively small
  • the pump outlet pressures of the flow rate servo pump 4, the first maximum flow frequency conversion pump 5, and the second maximum flow frequency conversion pump 6 are monitored.
  • the number of the flowmeters is the same as the number of the sensors.
  • the nth flowmeter 7-n and the nth pressure sensor 9-n are used to synchronously collect the pressure transmission, fluctuation frequency and flow change of the long-distance hydraulic pipeline in sections to realize long-distance
  • the real-time monitoring of the flow and pressure of the distance liquid supply pipeline 12 establishes the pressure-flow model of the long-distance pipeline system. .
  • the actuators on several hydraulic supports 16 in the hydraulic support group include columns 19, push jacks 22, side push jacks 14, balance jacks 17 and side protection jacks 18;
  • a digital flow valve group is arranged between the liquid reversing valve group 13 .
  • the digital flow valve group includes a first digital flow valve 15-1 and a second digital flow valve 15-2, and the two ends of the pushing jack 22 pass through the first digital flow valve 15-1 and the second digital flow valve 15 respectively.
  • -2 is connected with the electro-hydraulic reversing valve group.
  • Each hydraulic support actuator of the hydraulic support group also includes a flow meter 7 and a pressure sensor 9, the ninth flow meter 7-9 to the twenty-fourth flow meter 7-24 and the fourth pressure sensor 9-4 to
  • the nineteenth pressure sensor 9-19 is arranged on the two ends of the column 19, the push jack 22, the side push jack 14, the balance jack 17 and the side jack 18, and the opposite column 19, the push jack 22, the side push jack 14, and the balance jack 17 and the flow and pressure of the protection jack 18 are monitored. Combined with the pressure/flow dynamic characteristics of long pipelines, the pressure/flow demand law of multiple hydraulic actuators under time-varying loads is obtained.
  • the small-flow servo pump 4 implements small-flow liquid supply, and the first large-flow frequency conversion pump 5 and the second large-flow frequency conversion pump 6 perform large-flow liquid supply;
  • the small-flow servo pump 4 When performing small flow liquid supply, the large flow actuators include the column 19 for liquid supply and liquid replenishment, the small flow actuators include the push jack 22, the side push jack 14, the balance jack 17 and the side jack 18 for liquid supply, and the liquid supply
  • the loss of the pipeline 12 is used for fluid replacement, reducing the number of starts and frequency conversion intervals of the first large-flow variable-frequency pump 5 and the second large-flow variable-frequency pump 6, so as to realize throttling and voltage stabilization control.
  • the small-flow servo pump 4 performs fluid replenishment through the intelligent liquid supply system 1; the small-flow servo pump 14 can supply liquid to the small-flow actuator, supplement the liquid supply loss of the large-flow actuator and the long pipeline, and reduce large The number of starts of the flow rate variable frequency pump group realizes the function of throttling and voltage stabilization control.
  • the intelligent liquid supply system 1 is also provided with an emulsion tank 3.
  • the small flow servo pump 4 and the first The large flow frequency conversion pump 5 and the second large flow frequency conversion pump 6, and the first unloading valve 10 and the second unloading valve 11 are opened, and the small flow servo pump 4 is used to supply the intelligent liquid supply system 1 liquid, when the operating frequencies of the first large-flow frequency conversion pump 5 and the second large-flow frequency conversion pump 6 are stable, close the first unloading valve 10 and the second unloading valve 11, and use the first The large-flow variable-frequency pump 5 and the second large-flow variable-frequency pump 6 supply liquid to the hydraulic system, reducing the flow impact and pressure fluctuation of the intelligent liquid supply system, and using the small-flow servo pump 4 to realize soft-start control of the emulsion pumping station .
  • the monitoring and control system 2 is combined with the intelligent liquid supply system 1 to obtain the pressure/flow dynamic characteristics of the hydraulic system under different working conditions of strong time-varying loads, multiple actuators and support groups, and realize the pressure/flow rate of the emulsion pump station.
  • the flow predictive control realizes the precise matching of the first large-flow frequency conversion pump 5 , the second large-flow frequency conversion pump 6 and the small-flow servo pump 4 with the pressure/flow of the actuator.
  • the intelligent liquid supply system 1 and the monitoring and control system 2 form a closed-loop feedback to improve the rapid response and stability of underground high-pressure and large-flow liquid supply.
  • the hydraulic system is intelligently supplied, and the system pressure/flow monitoring parameters after the liquid supply will further optimize the prediction model and feed back to the intelligent liquid supply system 1 to achieve closed-loop feedback optimization. Improve the rapid response and stability of the large flow liquid supply system.
  • the small flow servo pump 4 uses the monitoring and control system 2 through the flow meter 7 and the pressure sensor 9, the small flow servo pump 4, the first large flow frequency conversion pump 5, the second large flow frequency conversion pump 6, the long-distance liquid supply pipeline 12 and the hydraulic support 16 each The flow actuator monitors the flow and pressure.
  • the periodic actions of the hydraulic support include lifting, lowering, pushing, and moving are taken as the time period unit, and the expected value of the hydraulic support within the period and the pressure/flow stability of the hydraulic system are used as the decision-making
  • the goal is to take the movement type and movement speed of each hydraulic support in the hydraulic support group as the decision space 1, in which the movement type determines the action sequence of the hydraulic support, and the fluid supply control determines the movement speed of the hydraulic support.
  • the second largest flow frequency conversion pump 6 and the liquid supply adjustment control of the liquid supply pipeline 12 are decision space 2, in which, according to the number of pump sets and the small flow servo pump 4, the first largest flow frequency conversion pump 5 and the second largest flow frequency conversion
  • the parameter setting of the pump 6 controls the adjustment range and accuracy range of the liquid supply flow, takes the action type of the hydraulic support and the adjustment of the liquid supply as the decision variables, and defines the combined action of the hydraulic support group within the same and different time ranges, including cross-execution of different actions and the same type The actions are executed synchronously.
  • the intelligent liquid supply system 1 is used to build a predictive control model for the combined action execution of the emulsion pump station fluid pressure/flow and the hydraulic support, and establish a collaborative control strategy for the hydraulic support and the emulsion pump station.
  • the monitoring system to perceive the action execution sequence and pressure variation characteristics of the actuators of the bracket, according to the periodic action rules of the actuators of the hydraulic bracket 16, predict the actions to be performed by the group of hydraulic brackets, and calculate the corresponding liquid demand for the emulsion, and then Control the pump station and unloading valve group in the liquid supply system in advance to compensate for the pressure loss and response lag in the long-distance power transmission process of the liquid supply system.
  • the pressure/flow dynamic characteristics of the multi-load actuators and the hydraulic support 16 support groups under different working conditions realize the precise matching of the pressure/flow of the pump and the actuator.
  • Step S1 data collection: run the liquid supply system, the monitoring control system 2 controls the small flow servo pump 4, the emulsion pump station, and the long-distance The pressure/flow rate of the liquid supply pipeline 12 is collected;
  • Step S2 establishing a pressure-flow model: the monitoring and control system 2 analyzes and processes the various data collected in step S1 to establish a pressure-flow model of the liquid supply pipeline 12;
  • Step S3. Obtain pressure-flow dynamic response: According to the established pressure-flow model, combined with the collected outlet pressure and flow data of the emulsion pump station, study the effect of multi-pump parallel time-sharing and synchronous liquid supply mode on the liquid supply pipe The shock fluctuation form caused by the road 12, analyzing the pressure transmission of the liquid supply pipeline 12, the fluctuation frequency and the flow change, and obtaining the pressure-flow dynamic response of the long-distance liquid supply pipeline 12 in real time;
  • Step S4 collecting data under real-time monitoring: real-time monitoring and collecting of the pressure/flow of several actuators;
  • Step S5. Summarize the pressure/flow demand law of the hydraulic system under time-varying load: combine the data collected in step S4 with the pressure-flow dynamic response to summarize the pressure/flow demand of the hydraulic system under time-varying load of several actuators law;
  • Step S6 obtain the pressure/flow characteristics: monitor each hydraulic support 16 or a combination of multiple hydraulic supports 16 under the conditions of lowering, pulling, pushing, lifting and different movement cycles of the hydraulic supports 16 Pressure/flow characteristics;
  • Step S7 obtain the dynamic prediction of pressure/flow: combine the pressure/flow characteristics obtained in step S6 with the flow demand law of the hydraulic system under time-varying loads, and dynamically predict the liquid demand of the system under the multi-working mode of several hydraulic supports;
  • Step S8 according to the current specific working conditions, dynamically match with the predicted liquid demand of the system under the multi-working mode of several hydraulic supports, so as to dynamically adjust the first large-flow frequency conversion pump 5 and the The liquid supply volume of the second large flow frequency conversion pump 6 and the small flow servo pump 4 matches the liquid demand volume of the hydraulic support group in real time.
  • Unexecuted state Taking the first hydraulic support 16-1 in the hydraulic support group as an example, when the hydraulic support 16-1 does not perform relevant actions, the pressure of the hydraulic system drops slowly, and the hydraulic system of the support is in a state of slow leakage.
  • the monitoring and control system The flow meter 7 and pressure sensor 9 of 2 monitor the pressure/flow of the pumping station, the long-distance liquid supply pipeline 12 and the actuators of each hydraulic support in real time, and upload it to the intelligent liquid supply system 1 for analysis and processing in real time, based on the monitoring control
  • the small-flow servo pump 4 starts, and realizes the liquid replenishment function under the control of the intelligent liquid supply system 1, avoiding the opening of other additional high-flow frequency conversion pumps, and avoiding the action of the first unloading valve 10 and the second unloading valve 11 , to achieve energy saving and voltage regulation.
  • the intelligent liquid supply monitoring and control system 2 monitors the pressure/flow rate of the small flow servo pump 4 in real time through the first flow meter 7-1 and the first pressure sensor 9-1, and the second flow meter 7-2 and the second pressure sensor 9-2 Real-time monitoring of the pressure/flow rate of the first large flow variable frequency pump 5, and the pressure/flow rate of the second large flow variable frequency pump 6 through the third flowmeter 7-3 and the third pressure sensor 9-3 Real-time monitoring, the pressure/flow real-time monitoring of the long-distance liquid supply pipeline 12 is carried out through the nth flow meter 7-n and the nth pressure sensor 9-n, and the pressure-flow dynamic response of the long-distance liquid supply system is obtained.
  • Elevated state taking the first hydraulic support 16-1 in the hydraulic support group as an example, when the first hydraulic support 16-1 is in the elevated state, the small flow servo pump 4 starts, and the first unloading valve 10 .
  • the second unloading valve 11 is opened until the first large flow frequency conversion pump 5 and the second large flow frequency conversion pump 6 reach a stable operating frequency, and the first unloading valve 10 and the second unloading valve 11 are closed , the first large-flow frequency conversion pump 5 and the second large-flow frequency conversion pump 6 supply liquid to the column 19 through the first electro-hydraulic reversing valve group 13-1, and the column 19 starts to rise.
  • the nineteenth flow Meter 7-19 to the twenty-second flow meter 7-22 and the fourteenth pressure sensor 9-14 to the seventeenth pressure sensor 9-17 are arranged on two columns in the plurality of column groups 19, for two
  • the flow and pressure of the upper and lower chambers of the column are monitored in real time, combined with the dynamic response of the long-distance liquid supply system to obtain the dynamic response law of the pressure-flow rate of the column 19 and fed back to the intelligent liquid supply system 1, and start the 4 pairs of small flow servo pumps
  • the column 19 performs real-time small-flow liquid supply and pressure supplementation, avoiding the opening of an additional large-flow variable frequency pump group, and realizes energy saving and voltage stabilization while improving the operation speed and accuracy of the column 19.
  • Stretching state Taking the first hydraulic support 16-1 in the hydraulic support group as an example, when the first hydraulic support 16-1 is in the state of pulling the support, the small flow servo pump 4 passes through the first electro-hydraulic reversing valve group 13- 1 Under the control of the intelligent liquid supply system, supply liquid to the push jack 22 according to the pressure-flow dynamic response of the push jack 22, the twenty-third flow meter 7-23, the twenty-fourth flow meter 7-24, the eighteenth flow meter The pressure sensor 9-18 and the nineteenth pressure sensor 9-19 monitor the pressure/flow of the push jack 22 in real time, and the push jack 22 is realized by the first digital flow valve 15-1 and the second digital flow valve 15-2.
  • the multiple hydraulic supports 16 of the hydraulic support group perform the racking action at the same time, and the monitoring and control system 2 monitors that the liquid supply required by the intelligent liquid supply system 1 exceeds the maximum flow rate of the small flow servo pump 4, the intelligent liquid supply system 1 is turned on
  • the large-flow frequency conversion pump group supplies liquid to the pushing jacks 22 of each hydraulic support 16 through the electro-hydraulic reversing valve group 13 .
  • Pushing state Taking the first hydraulic support 16-1 in the hydraulic support group as an example, when the first hydraulic support 16-1 is in the pushing state, the small flow servo pump 4 is in the monitoring control system 2 and the intelligent supply system. Under the adjustment and control of the hydraulic system 1, liquid is supplied to the push jack 22 through the first electro-hydraulic reversing valve group 13-1, and the piston rod is stretched out to push the scraper conveyor to the coal wall.
  • the small flow servo pump 4 is monitoring Under the adjustment and control of the control system 2 and the intelligent liquid supply system 1, the precise straightening of the conveyor is realized, and the intelligent and rapid adjustment of the straightness of the working face is realized.
  • the intelligent liquid supply System 1 starts the large-flow frequency conversion pump group to supply liquid to the push jack 22 of each hydraulic support through the electro-hydraulic reversing valve group 13 .
  • Operating state of the small flow actuator taking the first hydraulic support 16-1 in the hydraulic support group as an example, when the jack 22 is moved, several side push jacks (preferably, several side push jacks include the first side push jack 14-1, When the second side push jack 14-2, the third side push jack 14-3), the balance jack 17, and the side jack 18 are running under small flow execution conditions, the fourth pressure sensor 9-4 to the thirteenth pressure sensor 9-13 and the eighteenth pressure sensor 9-18 and the nineteenth pressure sensor 9-19 operate, the ninth flow meter 7-9 to the eighteenth flow meter 7-18 and the twenty-third flow meter 7-23 and The twenty-fourth flow meter 7-24 monitors the pressure/flow of each small flow actuator in real time under the control of the monitoring control system 2, and starts the small flow servo pump 4 to start the liquid supply under the control of the intelligent liquid supply system 1, without the need Turn on the extra high-flow frequency conversion pump to realize energy-saving liquid supply.
  • the intelligent liquid supply system 1 turns on the large flow rate
  • the frequency conversion pump group supplies liquid to each small flow actuator of each hydraulic support through the electro-hydraulic reversing valve group 13 .
  • the intelligent liquid supply system 1 and the monitoring and control system 2 realize the system pressure/ Dynamic forecasting of the flow rate, through the small flow servo pump 4 jointly controlling the emulsion pump station to realize the liquid supply and replenishment of the large flow actuator, to realize the pressure/flow supplement of the long-distance liquid supply pipeline 12 supply loss, and to achieve multi-flow execution Energy-saving and stable pressure intelligent liquid supply under the conditions of multiple working conditions of the mechanism; at the same time, the intelligent liquid supply system 1 and the monitoring control system 2 further form a closed-loop feedback optimization to improve the response accuracy of the hydraulic support intelligent liquid supply system, and realize underground high pressure and large flow.
  • the real-time matching of flow and pressure of multi-flow actuators under variable load conditions realizes energy-saving and stable pressure control of multi-pump linkage adaptive adjustment system pressure and flow in different working modes of the support.

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Abstract

公开了一种液压支架智能供液系统，包括：监测控制系统（2），监测控制系统（2）包括液压支架组、压力监测系统和流量监测系统以及电液换向阀组（13）；能够实时监测煤矿井下液压支架群的压力变动，并依据液压支架周期性工作流程和长管路动力传递特性，动态预测执行机构的需液量，实时调节多泵联动供液系统的供液量，实现支架组多工作模式下系统压力、流量的自适应调节，满足井下供液系统的智能化稳压和节能控制要求；还公开了使用该系统的方法。

Description

一种液压支架智能供液系统及工作方法 技术领域
本发明属于矿山装备领域，具体的是一种液压支架智能供液系统及工作方法。
背景技术
井下工作面液压支架液压系统是由多泵组成的联合供液系统、多缸工作机构及长管路共同组成，支架组多机构工作时执行机构所需流量时刻变化，导致系统压力剧烈变化，且叠加长管路动力传递的损失效应，液压支架供液系统与执行机构的连续流量匹配控制成为难题。
因此设计一种井下液压支架智能供液系统对实现液压支架的可靠工作，满足采煤工作面智能化需求具有积极意义。
发明内容
本发明提供了一种液压支架智能供液系统及工作方法，可以实现井下长距离供液过程中液压支架供液系统与执行机构需液量的实时匹配。
本发明解决上述技术问题采用的技术方案为：一种液压支架智能供液系统，包括：
监测控制系统，所述监测控制系统包括液压支架组和压力/流量监测系统以及电液换向阀组；
所述液压支架组包括若干并联设置的液压支架，所述液压支架包括若干执行机构；
所述压力/流量监测系统与所述液压支架组连接；
所述若干电液换向阀组与若干所述液压支架各执行机构一一对应连接；
智能供液系统，所述智能供液系统与所述压力/流量监测系统连接；
所述智能供液系统包括乳化液箱、乳化液泵站和小流量伺服泵；
所述乳化液箱与所述乳化液泵站和所述小流量伺服泵分别连接；
所述乳化液泵站包括第一大流量变频泵和第二大流量变频泵；
所述小流量伺服泵、所述第一大流量变频泵以及所述第二大流量变频泵并联设置并形成回路；
所述回路一端通过供液管路与电液换向阀组的进液口相连接；
所述回路另一端通过电液换向阀组回液口与回液管路相连接。
进一步地，若干所述执行机构包括若干立柱、推移千斤顶、侧推千斤顶、平衡千斤顶、护帮千斤顶，若干所述立柱、所述推移千斤顶、所述侧推千斤顶、所述平衡千斤顶以及护帮千斤顶分别与所述电液换向阀组并联设置，所述推移千斤顶与所述电液换向阀之间设置有若干所述数字流量阀组。
进一步地，所述压力/流量监测系统包括若干流量计和若干压力传感器，每个所述立柱、所述推移千斤顶、所述侧推千斤顶、所述平衡千斤顶以及所述护帮千斤顶的两端均设置有所述流量计和所述压力传感器；所述小流量伺服泵、所述第一大流量变频泵、所述第二大流量变频泵的出口处和若干所述电液换向阀组进液口处均设置有所述流量计和所述压力传感器。
进一步地，所述小流量伺服泵由智能供液系统进行控制；所述第一大流量变频泵、第二大流量变频泵通过所述电液换向阀组向推移千斤顶的活塞腔内供液。
进一步地，还包括第一卸载阀和第二卸载阀，所述第一卸载阀设置于所述第一大流量变频泵与所述供液管路之间，所述第二卸载阀设置于所述第二大流量变频泵与所述供液管路之间。
还提供了一种液压支架智能供液系统的工作方法，包括如下步骤：
步骤S1、采集数据：运行所述供液系统，所述监测控制系统通过若干所述流量计与压力传感器对所述小流量伺服泵、所述乳化液泵站、长距离所述供液管路的压力/流量进行采集；
步骤S2、建立压力—流量模型：所述监测控制系统对步骤S1中采集的各项数据进行分析处理建立所述供液管路的压力—流量模型；
步骤S3、获取压力—流量动态响应：依据建立的压力—流量模型，结合采集的所述乳化液泵站出口压力及流量数据，研究多泵并联分时及同步供液模式对所述供液管路造成的冲击波动形式，分析所述供液管路的压力传递，波动频率及流量变化，实时获取所述长距离供液管路的压力—流量动态响应；
步骤S4、采集实时监测下数据：对若干所述执行机构的压力/流量进行实时监测和采集；
步骤S5、总结时变负载下液压系统的压力/流量需求规律：将步骤S4中采集的数据，结合压力—流量动态响应，总结若干所述执行机构在时变负载下液压系统的压力/流量需求规律；
步骤S6、得到压力/流量特性：监测每个所述液压支架或者多个所述液压支架组合在降架、拉架、推溜、升架及所述液压支架不同运动周期变化条件下的压力/流量特性；
步骤S7、得到压力/流量的动态预测：将步骤S6中得到的压力/流量特性，结合时变负载下液压系统的流量需求规律，动态预测若干液压支架多工作模式下系统需液量；
步骤S8、根据当前具体工况，与预测得到的若干液压支架多工作模式下系统需液量的进行动态匹配，从而动态调节所述供液系统中所述第一大流量变频泵、所述第二大流量变频泵和所述小流量伺服泵的供液量，实时匹配液压支架组的需液量；
进一步地，当液压支架的各执行机构开始降架，拉架，推溜，升架多工作模式组合时，智能 供液系统结合监测控制系统时变负载下的压力/流量需求规律，实现液压支架多周期多工作模式下系统压力—流量动态预测，通过小流量伺服泵联合控制乳化液泵站实现大流量执行机构的供液，以及实现对小流量执行机构、长距离的供液管路供液损失进行流量压力补充，结合监测控制系统实现多执行机构多工况条件下的节能稳压智能供液；
进一步地，所述小流量伺服泵在执行小流量供液时对大流量执行机构包括立柱进行供液及补液，小流量执行机构包括推移千斤顶、侧推千斤顶、平衡千斤顶和护帮千斤顶进行供液，对长距离的供液管路损失进行补液。
与现有技术相比，本发明的有益效果为；
本发明提供了一种液压支架智能供液系统及工作方法，该系统能够实时监测煤矿井下液压支架群的压力变动，并依据液压支架周期性工作流程和长管路动力传递特性，动态预测执行机构的需液量，实时调节多泵联动供液系统的供液量，实现支架组多工作模式下系统压力流量的自适应调节，满足井下供液系统的智能化稳压和节能控制要求。
压力/流量附图说明
图1为一种液压支架智能供液系统的结构示意图。
图中：1为智能供液系统；2为监测控制系统；3为乳化液箱；4为小流量伺服泵；5为第一大流量变频泵；6为第二大流量变频泵；7为流量计，其中，7-1第一流量计、7-2为第二流量计……7-n为第n流量计；8为回液管路；9为压力传感器，其中，9-1为第一压力传感器、9-2为第二压力传感器……9-n为第n压力传感器；10为第一卸载阀；11为第二卸载阀；12为供液管路；13为电液换向阀组，其中13-1为第一电液换向阀组、13-2为第二电液换向阀组……13-n为第n电液换向阀组；14-1为第一侧推千斤顶、14-2为第二侧推千斤顶、14-3为第三侧推千斤顶；15为数字流量阀组；15-1为第一数字流量阀；15-2为第二数字流量阀；16为液压支架，其中，16-1为第一液压支架，16-2为第二液压支架……16-n为第n液压支架；17为平衡千斤顶；18为护帮千斤顶；19为立柱；20为第一安全阀；21为第二安全阀；22为推移千斤顶。
说明：在说明书附图中，表示电液换向阀组的标注13以及表示液压支架的标注16并未在图中显示，是为了在具体实施方式中方便描述。
具体实施方式
为了便于理解本发明，下面将参照相关附图对本发明进行更加全面的描述，附图中给出了本发明的若干实施例，但是本发明可以通过不同的形式来实现，并不限于文本所描述的实施例，相反的，提供这些实施例是为了使对本发明公开的内容更加透彻全面。
实施例1
本实施例提供一种优选实施方案，一种液压支架智能供液系统，如图1所示，本实施方案包括监测控制系统2和智能供液系统1，所述监测控制系统2包括液压支架组和压力/流量监测系统(对应图示中压力-流量监测部分)以及电液换向阀组13，图中可以看出，所述电液换向阀组13包括多组，这里为了方便描述，分别定义为第一电液换向阀组13-1、第二电液换向阀组13-2……第n电液换向阀组13-n。
所述液压支架组包括若干并联设置的液压支架16，所述液压支架16包括若干执行机构。若干所述执行机构包括若干立柱19、推移千斤顶22、若干侧推千斤顶14、平衡千斤顶17、护帮千斤顶18，若干所述立柱19、所述推移千斤顶22、若干所述侧推千斤顶14、所述平衡千斤顶17以及护帮千斤顶18分别与所述电液换向阀组13并联设置，所述推移千斤顶22与所述电液换向阀组13之间设置有若干所述数字流量阀组。
所述数字流量阀组包括第一数字流量阀15-1和第二数字流量阀15-2，所述第一数字流量阀15-1与所述第二数字流量阀15-2分别设置于所述推移千斤顶22与所述第一电液换向阀组13-1连接的两线路上。
所述压力/流量监测系统与所述液压支架组连接；所述压力/流量监测系统包括若干流量计7和若干压力传感器9，每个所述立柱19、所述推移千斤顶22、所述侧推千斤顶14、所述平衡千斤顶17以及所述护帮千斤顶18的两端均设置有所述流量计7和所述压力传感器9；所述小流量伺服泵4、所述第一大流量变频泵5、所述第二大流量变频泵6的出口处和若干所述电液换向阀组13进液口处均设置有所述流量计7和所述压力传感器9。
所述若干电液换向阀组13与若干所述液压支架16的执行机构一一对应连接；所述智能供液系统1与所述压力/流量监测系统连接。
所述智能供液系统1包括乳化液箱3、乳化液泵站和小流量伺服泵4，所述小流量伺服泵4由智能供液系统1进行控制；所述第一大流量变频泵5、第二大流量变频泵6通过所述电液换向阀组13向推移千斤顶22的活塞腔内供液。所述乳化液箱3与所述乳化液泵站和所述小流量伺服泵4分别连接；所述乳化液泵站包括第一大流量变频泵5和第二大流量变频泵6；所述小流量伺服泵4、所述第一大流量变频泵5以及所述第二大流量变频泵6并联设置并形成回路；所述回路一端通过供液管路12与若干所述电液换向阀组13的进液口分别连接；所述回路另一端通过通过若干电液换向阀组13回液口与回液管路8相连接。
本实施方案还包括第一卸载阀10和第二卸载阀11，所述第一卸载阀10设置于所述第一大流量变频泵5与所述供液管路12之间，所述第二卸载阀11设置于所述第二大流量变 频泵6与所述供液管路12之间。
所述的监测控制系统2控制多泵并联联合供液为井下液压系统提供所需压力与流量，通过流量计7和压力传感器9对乳化液泵站包括小流量伺服泵4、第一大流量变频泵5、第二大流量变频泵6、长距离供液管路12的压力/流量进行分段及实时监测，通过控制系统对采集数据进行分析处理，初步建立起长距离供液系统的压力—流量模型，结合泵站出口压力数据，研究多泵并联分时及同步供液模式对所述供液管路造成的冲击波动形式，分析所述供液管路的压力传递，波动频率及流量变化，实时获取所述长距离供液管路的压力—流量动态响应；
所述智能供液系统1包括小流量伺服泵4、大流量变频泵组和卸载阀组；所述大流量变频泵组包括第一大流量变频泵5和第二大流量变频泵6，所述卸载阀组包括第一卸载阀10和第二卸载阀11；所述小流量伺服泵4、第一大流量变频泵5、第二大流量变频泵6并联形成回路，回路的一端设置有供液管路12，并通过供液管路12与电液换向阀组13的进液口连接，回路的另一端设置有回液管路8，并通过电液换向阀组13的回液口与回液管路8相连接；所述第一卸载阀10设置在第一大流量变频泵5与供液管路12之间，所述第二卸载阀11设置在第二大流量变频泵6与供液管路12之间。
所述智能供液系统1在大流量变频泵组的基础上并联了小流量伺服泵，由小流量伺服泵4、大流量变频泵组以及卸载阀组组成，建立起新型供液系统，实现对液压支架组各流量执行机构，长管路供液损失以及支架液压系统进行流量补充，结合监测控制系统2实现液压支架组各液压支架上的执行机构在多工况条件下的智能供液及稳压控制。同时，智能供液系统1与监测控制系统2进一步形成闭环反馈，基于智能供液系统1利用监测控制系统2的压力—流量动态响应对液压系统进行智能供液，供液完毕后监测控制系统2将再次采集分析系统的压力/流量参数，强化液压系统压力—流量动态预测的准确度，并再次与智能供液系统1相结合，提高智能供液系统1的响应速度与稳定性，实现闭环反馈优化，进而得到各监测点的压力/流量特性，能够对乳化液泵站压力/流量预测控制，实现第一大流量变频泵5、所述第二大流量变频泵6以及小流量伺服泵4与执行机构压力/流量的精确匹配，提高了井下高压大流量供液系统的快速响应性及稳定性。
需要说明的是，若干所述流量计包括第一流量计7-1、第二流量计7-2、第三流量计7-3、第四流量计7-4……第n流量计7-n，所述第一流量计7-1、所述第二流量计7-2、所述第三流量计7-3分别对小流量伺服泵4、第一大流量变频泵5、第二大流量变频泵6的泵出口流量进行监测，所述第四流量计7-4对泵站出口总流量进行监测，若干所述压力传感器包 括第一压力传感器9-1、第二压力传感器9-2、第三压力传感器9-3……第n压力传感器9-n，所述第一压力传感器9-1、所述第二压力传感器9-2、所述第三压力传感器9-3分别对小流量伺服泵4、第一大流量变频泵5、第二大流量变频泵6的泵出口压力进行监测。所述流量计的设置个数与所述传感器设置个数一致。基于长距离供液系统回路阻力特性，利用所述第n流量计7-n与所述第n压力传感器9-n同步分段采集长距离液压管道的压力传递、波动频率及流量变化，实现长距离供液管路12流量与压力的实时监测，建立长距离管路系统压力—流量模型。。
需要说明的是，所述液压支架组中若干液压支架16上的执行机构包括立柱19、推移千斤顶22、侧推千斤顶14、平衡千斤顶17和护帮千斤顶18；其中，所述推移千斤顶22与电液换向阀组13之间设置有数字流量阀组。所述数字流量阀组包括第一数字流量阀15-1和第二数字流量阀15-2，所述推移千斤顶22的两端分别通过第一数字流量阀15-1、第二数字流量阀15-2与电液换向阀组连接。
所述液压支架组各液压支架执行机构上还包括有流量计7与压力传感器9，所述第九流量计7-9至第二十四流量计7-24以及第四压力传感器9-4至第十九压力传感器9-19设置在立柱19、推移千斤顶22、侧推千斤顶14、平衡千斤顶17和护帮千斤顶18的两端，对立柱19、推移千斤顶22、侧推千斤顶14、平衡千斤顶17和护帮千斤顶18的流量与压力进行监测。结合长管路压力/流量动态特性，获得多液压执行机构在时变负载下的压力/流量需求规律。
需要说明的是，所述小流量伺服泵4执行小流量供液，所述第一大流量变频泵5、所述第二大流量变频泵6执行大流量供液；所述小流量伺服泵4在执行小流量供液时对大流量执行机构包括立柱19进行供液及补液，小流量执行机构包括推移千斤顶22、侧推千斤顶14、平衡千斤顶17和护帮千斤顶18进行供液，对供液管路12损失进行补液，减少所述第一大流量变频泵5、所述第二大流量变频泵6的启动次数与变频区间，实现节流稳压控制作用。
所述小流量伺服泵4通过智能供液系统1进行补液；所述小流量伺服泵14可对小流量执行机构进行供液，对大流量执行机构及长管路供液损失进行补充，减少大流量变频泵组启动次数，实现节流稳压控制作用。
需要说明的是，所述智能供液系统1内还设置有乳化液箱3，当智能供液系统1需要乳化液箱3提供乳化液时，启动所述小流量伺服泵4、所述第一大流量变频泵5和所述第二大流量变频泵6，并打开所述第一卸载阀10和所述第二卸载阀11，利用所述小流量伺服泵4为智能供液系统1进行供液，当所述第一大流量变频泵5和所述第二大流量变频泵6的工 作频率稳定后，关闭所述第一卸载阀10和所述第二卸载阀11，利用所述第一大流量变频泵5和所述第二大流量变频泵6为液压系统进行供液，减小智能供液系统流量冲击和压力波动，利用所述小流量伺服泵4实现乳化液泵站软启动控制。
作为优选的，将监测控制系统2与智能供液系统1相结合，得到液压系统在强时变负载多执行机构以及支架组不同工况下的压力/流量动态特性，实现乳化液泵站压力/流量预测控制，实现第一大流量变频泵5、所述第二大流量变频泵6以及小流量伺服泵4与执行机构压力/流量的精确匹配。智能供液系统1与监测控制系统2形成闭环反馈，提高井下高压大流量供液的快速响应性及稳定性。基于监测控制系统2的系统压力—流量动态响应，对液压系统进行智能供液，供液后的系统压力/流量监测参数将进一步优化预测模型并反馈至智能供液系统1，实现闭环反馈优化，提高大流量供液系统的快速响应性及稳定性。
利用所述监测控制系统2通过流量计7与压力传感器9对小流量伺服泵4、第一大流量变频泵5、第二大流量变频泵6，长距离供液管路12以及液压支架16各流量执行机构进行流量和压力监测，同时以液压支架周期性动作包括升架、降架、推溜、移架为时间周期单位，以周期内液压支架的动作期望值和液压系统压力/流量稳定为决策目标，以液压支架组各液压支架运动类型及运动速度为决策空间一，其中运动类型决定液压支架动作顺序，供液控制决定液压支架运动速度，以小流量伺服泵4、第一大流量变频泵5、第二大流量变频泵6以及供液管路12的供液调节控制为决策空间二，其中依据泵组数量及小流量伺服泵4、第一大流量变频泵5以及第二大流量变频泵6的参数设置，控制供液流量调节范围及精度范围，以液压支架动作类型及供液调节为决策变量，定义相同及不同时间范围内液压支架组组合动作，包括不同动作交叉执行及相同类型动作同步执行，通过智能供液系统1构建乳化液泵站供液压力/流量与液压支架组合动作执行的预测控制模型，建立液压支架与乳化液泵站的协同控制策略。通过监测系统感知支架执行机构的动作执行顺序和压力变动特性，依据液压支架16各执行机构周期性动作规律，预判成组液压支架即将执行的动作，并计算相应的乳化液需液量，继而提前控制供液系统中的泵站和卸载阀组，以补偿供液系统长距离动力输送过程的压力损失和响应滞后，将监测控制系统与智能供液系统相结合，得到液压系统在强时变负载多执行机构以及液压支架16支架组不同工况下的压力/流量动态特性，实现泵与执行机构压力/流量的精确匹配。
还提供了一种所述的液压支架智能供液系统的工作方法，包括如下步骤：
步骤S1、采集数据：运行所述供液系统，所述监测控制系统2通过若干所述流量计7与压力传感器9对所述小流量伺服泵4、所述乳化液泵站、长距离所述供液管路12的压力/流量 进行采集；
步骤S2、建立压力—流量模型：所述监测控制系统2对步骤S1中采集的各项数据进行分析处理建立所述供液管路12的压力—流量模型；
步骤S3、获取压力—流量动态响应：依据建立的压力—流量模型，结合采集的所述乳化液泵站出口压力及流量数据，研究多泵并联分时及同步供液模式对所述供液管路12造成的冲击波动形式，分析所述供液管路12的压力传递，波动频率及流量变化，实时获取所述长距离供液管路12的压力—流量动态响应；
步骤S4、采集实时监测下数据：对若干所述执行机构的压力/流量进行实时监测和采集；
步骤S5、总结时变负载下液压系统的压力/流量需求规律：将步骤S4中采集的数据，结合压力—流量动态响应，总结若干所述执行机构在时变负载下液压系统的压力/流量需求规律；
步骤S6、得到压力/流量特性：监测每个所述液压支架16或者多个所述液压支架16组合在降架、拉架、推溜、升架及所述液压支架16不同运动周期变化条件下的压力/流量特性；
步骤S7、得到压力/流量的动态预测：将步骤S6中得到的压力/流量特性，结合时变负载下液压系统的流量需求规律，动态预测若干液压支架多工作模式下系统需液量；
步骤S8、根据当前具体工况，与预测得到的若干液压支架多工作模式下系统需液量的进行动态匹配，从而动态调节所述供液系统中所述第一大流量变频泵5、所述第二大流量变频泵6和所述小流量伺服泵4的供液量，实时匹配液压支架组的需液量。
本实施方案执行各状态的具体方式为：
未执行状态：以液压支架组中的第一液压支架16-1为例，当液压支架16-1未执行相关动作时，液压系统压力缓慢下降，支架液压系统处于缓慢漏液状态，监测控制系统2的流量计7与压力传感器9对泵站，长距离供液管路12以及各液压支架执行机构的压力/流量进行实时监测，并实时上传至智能供液系统1进行分析处理，基于监测控制系统2所提供的响应数据，小流量伺服泵4启动，在智能供液系统1的控制下实现补液功能，避免其他额外大流量变频泵开启，避免第一卸载阀10、第二卸载阀11动作，实现节能稳压。智能供液监测控制系统2通过第一流量计7-1以及第一压力传感器9-1对所述小流量伺服泵4进行压力/流量实时监测，第二流量计7-2以及第二压力传感器9-2对所述第一大流量变频泵5进行压力/流量实时监测，通过第三流量计7-3以及第三压力传感器9-3对所述第二大流量变频泵6进行压力/流量实时监测，通过第n流量计7-n与第n压力传感器9-n对长管路供液管路12进行压力/流量实时监测，得到长距离供液系统压力—流量动态响应。
升架状态：以液压支架组中的第一液压支架16-1为例，当第一液压支架16-1处于升 架状态下，所述小流量伺服泵4启动，所述第一卸载阀10、所述第二卸载阀11开启直到所述第一大流量变频泵5、所述第二大流量变频泵6达到稳定工作频率，所述第一卸载阀10与所述第二卸载阀11关闭，所述第一大流量变频泵5、所述第二大流量变频泵6通过第一电液换向阀组13-1向所述立柱19供液，所述立柱19开始升起，当所述立柱19上升至顶梁与顶板接触时，随外负载增大所述立柱19下腔压力达到所述第一大流量变频泵5、所述第二大流量变频泵6的设定压力值，所述第一大流量变频泵5、所述第二大流量变频泵6停止供液，当顶部外负载进一步增大，所述立柱19处于溢流承载阶段，所述立柱19活塞杆腔压力达到第一安全阀20、第二安全阀21的调定压力，第一安全阀20、第二安全阀21开启卸载，所述立柱19下腔释放部分液体，以图1作为示例，第十九流量计7-19至第二十二流量计7-22和第十四压力传感器9-14至第十七压力传感器9-17设置在若干所述立柱组19中的两个立柱上，对两个立柱的上下腔流量与压力进行实时监测，结合长距离供液系统的动态响应获得所述立柱19压力—流量的动态响应规律并反馈至智能供液系统1，启动所述小流量伺服泵4对所述立柱19进行实时小流量供液补压，避免额外大流量变频泵组开启，在提高所述立柱19动作速度与精度的同时实现节能稳压。
降架状态：以液压支架组中的第一液压支架16-1为例，当第一液压支架16-1处于降架状态时，所述第一大流量变频泵5、所述第二大流量变频泵6开启工作，通过第一电液换向阀组13-1向所述立柱19上腔供液，所述立柱19下腔液体通过所述回液管路8回到所述乳化液箱3，所述小流量伺服泵4在所述智能供液系统1的调控下开启，实现所述立柱19下腔液体的加速回流，提高液压支架降架速度。
拉架状态：以液压支架组中的第一液压支架16-1为例，当第一液压支架16-1处于拉架状态时，所述小流量伺服泵4通过第一电液换向阀组13-1在智能供液系统的控制下，按照推移千斤顶22的压力—流量动态响应向推移千斤顶22供液，第二十三流量计7-23、第二十四流量计7-24，第十八压力传感器9-18、第十九压力传感器9-19实时监测所述推移千斤顶22的压力/流量，通过第一数字流量阀15-1和第二数字流量阀15-2实现所述推移千斤顶22收缩将整个液压支架拉向煤壁，提高拉架精度，降低其他大流量变频泵的开启次数实现节能高效控制。当所述液压支架组多液压支架16同时执行拉架动作，监测控制系统2监测到智能供液系统1所需供液量超过所述小流量伺服泵4的最大流量时，智能供液系统1开启大流量变频泵组通过电液换向阀组13向各液压支架16的推移千斤顶22进行供液。
推溜状态：以液压支架组中的第一液压支架16-1为例，当第一液压支架16-1处于推溜工况时，所述小流量伺服泵4在监测控制系统2及智能供液系统1的调节控制下通过第一 电液换向阀组13-1向推移千斤顶22供液，活塞杆伸出，将刮板输送机推向煤壁，所述小流量伺服泵4在监测控制系统2及智能供液系统1的调节控制下实现输送机的精准调直，实现工作面直线度智能化的快速调整。当所述液压支架组中的多液压支架16同时执行推溜动作，监测控制系统2监测到智能供液系统1所需供液量超过所述小流量伺服泵4的最大流量时，智能供液系统1开启大流量变频泵组通过电液换向阀组13向各液压支架的推移千斤顶22进行供液。
小流量执行机构运行状态：以液压支架组中的第一液压支架16-1为例，当推移千斤顶22，若干侧推千斤顶(优选地，若干侧推千斤顶包括第一侧推千斤顶14-1、第二侧推千斤顶14-2、第三侧推千斤顶14-3)，平衡千斤顶17，护帮千斤顶18在小流量执行工况下运行时，第四压力传感器9-4至第十三压力传感器9-13和第十八压力传感器9-18以及第十九压力传感器9-19运行，第九流量计7-9至第十八流量计7-18和第二十三流量计7-23以及第二十四流量计7-24在监测控制系统2的控制下对各小流量执行机构压力/流量进行实时监测，在智能供液系统1的控制下启动小流量伺服泵4开启供液，无需开启额外大流量变频泵，实现节能供液。当所述液压支架组中多液压支架16的小流量执行机构同时动作，监测控制系统2监测到系统所需供液量超过小流量伺服泵4的最大流量时，智能供液系统1开启大流量变频泵组通过电液换向阀组13向各液压支架的各小流量执行机构进行供液。
组合工况：当液压支架组开始执行降架，拉架，推溜，升架多工作模式组合动作时，智能供液系统1与监测控制系统2实现液压支架组多周期多工作模式下系统压力/流量动态预测，通过小流量伺服泵4联合控制乳化液泵站实现大流量执行机构的供液与补液，实现长距离的供液管路12供液损失的压力/流量补充，结实现多流量执行机构多工况条件下的节能稳压智能供液；同时，智能供液系统1与监测控制系统2进一步形成闭环反馈优化，提高液压支架智能供液系统的响应精度，实现井下高压大流量强时变负载条件下多流量执行机构的流量与压力的实时匹配，实现支架不同工作模式的多泵联动自适应调节系统压力和流量的节能稳压控制。
上述结合附图对本发明进行了示例性描述，显然本发明具体实现并不受上述方式的限制，只要采用了本发明的方法构思和技术方案进行的这种非实质改进，或未经改进将本发明的构思和技术方案直接应用于其他场合的，均在本发明的保护范围之内。

Claims (9)

  1. 一种液压支架智能供液系统，其特征在于，包括：
    监测控制系统(2)，所述监测控制系统(2)包括液压支架组和压力/流量监测系统以及电液换向阀组(13)；
    所述液压支架组包括若干并联设置的液压支架(16)，所述液压支架(16)包括若干执行机构；
    所述压力/流量监测系统包括若干流量计(7)与压力传感器(9)
    所述压力/流量监测系统与所述液压支架组连接；
    所述若干电液换向阀组(13)与若干所述液压支架(16)执行机构一一对应连接；
    智能供液系统(1)，所述智能供液系统(1)与所述压力/流量监测系统连接；
    所述智能供液系统(1)包括乳化液箱(3)、乳化液泵站和小流量伺服泵(4)；
    所述乳化液箱(3)与所述乳化液泵站和所述小流量伺服泵(4)分别连接；
    所述乳化液泵站包括第一大流量变频泵(5)和第二大流量变频泵(6)；
    所述小流量伺服泵(4)、所述第一大流量变频泵(5)以及所述第二大流量变频泵(6)并联设置并形成回路；
    所述回路一端通过供液管路(12)与电液换向阀组(13)的进液口相连接；
    所述回路另一端通过电液换向阀组(13)回液口与回液管路(8)相连接。
  2. 根据权利要求1所述的一种液压支架智能供液系统，其特征在于：若干所述执行机构包括若干立柱(19)、推移千斤顶(22)、若干侧推千斤顶(14)、平衡千斤顶(17)、护帮千斤顶(18)，若干所述立柱(19)、所述推移千斤顶(22)、若干所述侧推千斤顶(14)、所述平衡千斤顶(17)以及护帮千斤顶(18)分别与所述电液换向阀组(13)并联设置，所述推移千斤顶(22)与所述电液换向阀组(13)之间设置有若干所述数字流量阀组(15)。
  3. 根据权利要求2所述的一种液压支架智能供液系统，其特征在于：所述压力/流量监测系统包括若干流量计(7)和若干压力传感器(9)，每个所述立柱(19)、所述推移千斤顶(22)、所述侧推千斤顶(14)、所述平衡千斤顶(17)以及所述护帮千斤顶(18)的两端均设置有所述流量计(7)和所述压力传感器(9)；所述小流量伺服泵(4)、所述第一大流量变频泵(5)、所述第二大流量变频泵(6)的出口处和若干所述电液换向阀组(13)进液口处均设置有所述流量计(7)和所述压力传感器(9)。
  4. 根据权利要求3所述的一种液压支架智能供液系统，其特征在于：所述小流量伺服泵(4)由智能供液系统(1)进行控制；所述第一大流量变频泵(5)、第二大流量变频泵(6)通过所述电液换向阀组(13)向推移千斤顶(22)的活塞腔内供液。
  5. 根据权利要求4所述的一种液压支架智能供液系统，其特征在于：所述数字流量阀组(15)包括第一数字流量阀(15-1)和第二数字流量阀(15-2)，所述第一数字流量阀(15-1)与所述第二数字流量阀(15-2)分别设置于所述推移千斤顶(22)与所述电液换向阀连接的两线路上。
  6. 根据权利要求5所述的一种液压支架智能供液系统，其特征在于：还包括第一卸载阀(10)和第二卸载阀(11)，所述第一卸载阀(10)设置于所述第一大流量变频泵(5)与所述供液管路(12)之间，所述第二卸载阀(11)设置于所述第二大流量变频泵(6)与所述供液管路(12)之间。
  7. 一种基于权利要求1-6所述的液压支架智能供液系统的工作方法，其特征在于，包括如下步骤：
    步骤S1、采集数据：运行所述供液系统，所述监测控制系统(2)通过若干所述流量计(7)与压力传感器(9)对所述小流量伺服泵(4)、所述乳化液泵站、长距离所述供液管路(12)的压力/流量进行采集；
    步骤S2、建立压力—流量模型：所述监测控制系统(2)对步骤S1中采集的各项数据进行分析处理建立所述供液管路(12)的压力—流量模型；
    步骤S3、获取压力—流量动态响应：依据建立的压力—流量模型，结合采集的所述乳化液泵站出口压力及流量数据，研究多泵并联分时及同步供液模式对所述供液管路(12)造成的冲击波动形式，分析所述供液管路(12)的压力传递，波动频率及流量变化，实时获取所述长距离供液管路(12)的压力—流量动态响应；
    步骤S4、采集实时监测下数据：对若干所述执行机构的压力/流量进行实时监测和采集；
    步骤S5、总结时变负载下液压系统的压力/流量需求规律：将步骤S4中采集的数据，结合压力—流量动态响应，总结若干所述执行机构在时变负载下液压系统的压力/流量需求规律；
    步骤S6、得到压力/流量特性：监测每个所述液压支架(16)或者多个所述液压支架(16)组合在降架、拉架、推溜、升架及所述液压支架(16)不同运动周期变化条件下的压力/流量特性；
    步骤S7、得到压力/流量的动态预测：将步骤S6中得到的压力/流量特性，结合时变负载下液压系统的流量需求规律，动态预测若干液压支架多工作模式下系统需液量；
    步骤S8、根据当前具体工况，与预测得到的若干液压支架多工作模式下系统需液量的进行动态匹配，从而动态调节所述供液系统中所述第一大流量变频泵(5)、所述第二大流量变频泵(6)和所述小流量伺服泵(4)的供液量，实时匹配液压支架组的需液量。
  8. 根据权利要求7所述的液压支架智能供液系统的工作方法，其特征在于：当液压支架(16)的各执行机构开始降架，拉架，推溜，升架多工作模式组合时，智能供液系统(1)结合监测控制系统(2)时变负载下的压力/流量需求规律，实现液压支架(16)多周期多工作模式下系统压力—流量动态预测，通过小流量伺服泵(4)联合控制乳化液泵站实现大流量执行机构的供液，以及实现对小流量执行机构、长距离的供液管路(12)供液损失进行流量压力补充，结合监测控制系统(2)实现多执行机构多工况条件下的节能稳压智能供液。
  9. 根据权利要求8所述的液压支架智能供液系统的工作方法，其特征在于：所述小流量伺服泵(4)在执行小流量供液时对大流量执行机构包括立柱(19)进行供液及补液，小流量执行机构包括推移千斤顶(22)、侧推千斤顶(14)、平衡千斤顶(17)和护帮千斤顶(18)进行供液，对长距离的供液管路(12)损失进行补液。
PCT/CN2022/107632 2021-07-28 2022-07-25 一种液压支架智能供液系统及工作方法 WO2023005878A1 (zh)

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