煤矿悬臂式掘进机多信息监测系统设计与研究

Design and research on multi-information monitoring system for roadheader

针对目前悬臂式掘进机作业数据可视化差、可靠性低的问题,提出了一种基于多传感分布的多信息监测系统,设计了系统整体框架,实现了监测程序的可靠运行。首先,分析了悬臂式掘进机远程监测的工作特性,采用降噪去雾算法对现场图片进行增亮与清晰化处理,提升图像质量,达到远程实时视频监测水平,结合瓦斯与温湿度传感器实现了掘进环境监测;其次,以掘进机截割头位置作为其作业空间边界,建立掘进机截割头位姿与运行轨迹方程,采用油缸位移信号与倾角信号冗余算法,实时监测掘进机截割空间位置,实现截割头空间位置在线监测;然后,基于朗伯-比尔定律,采用透射法,设计了油液污染度实测系统,结合温度、液位与流量传感器,实现了掘进机油液状态的在线监测;进而,基于指数退化方法建立截割部轴承的剩余使用寿命预测模型,嵌入到监测系统中,实时显示掘进机各关键部件的性能曲线,实现了关键部件的寿命监测;最后,利用多传感分布方法采集信号,采用多信息融合方法,通过TCP协议,结合PLC网口通讯,远程采集温度、压力、振动等信号,进行实时可视化及故障趋势分析,形成掘进机工作环境状况、截割状态、油液状态、寿命预测等方面的多信息监测系统,为实现掘进机的智能化提供了理论和技术支撑。

Aiming at the problems of poor visualization and low reliability of roadheader operation data,a multi-information monitoring system based on multi-sensor distribution is proposed,and the overall framework of the system is designed to realize the reliable operation of the monitoring program.Firstly,the working characteristics of roadheader remote monitoring are analyzed,and the noise reduction and fog removal algorithm are used to enhance the brightness and clearness processing of the field pictures,so as to improve the image quality and achieve the level of remote real-time video monitoring.Combined with gas and temperature sensors,the heading environment monitoring is realized.Secondly,the position of roadheader’s cutting head is taken as its operating space boundary,and the pose and running trajectory equations of roadheader’s cutting head are established. The redundancy algorithm of cylinder displacement signal and in-clination signal are used to monitor the cutting space position of roadheader in real time. Thirdly, based on the Lambert- Beer law and transmission method, an oil contamination measurement system is designed to realize the online monitoring of oil state. Fourthly, based on the exponential degradation method, the residual service life model of cutting part bearing is established, which is embedded into the monitoring system to display the performance curves of the key components of the roadheader in real time, and the life monitoring of the key components is realized. Finally, through the TCP protocol, and combining the PLC communication, the signals, such as temperature, pressure, and vibration, are remotely acquisited. The method of multiple information fusion is adopted to obtain the data real-time visualization and the failure trend ana-lysis, which form the multi-information monitoring system containing environment, cutting state, oil state, life prediction and other aspects of the roadheader, in order to provide a theoretical and technical support for realizing intelligent mining.