Stability mechanism and control of the pumpable supports in longwall recovery room

The load-bearing performance(LBP)of pumpable supports(PPS)is crucial for the stability of longwall pre-driven recovery room(PRR)surrounding rock.However,the unbalanced bearing coefficient(UBC)of the PPS(undertaking unequal load along the mining direction)has not been investigated.A mechanical model of the PRR was established,considering the main roof cantilever beam structure,to derive an assessment formula for the load,the failure criteria,and the UBC of the PPS.Subsequently,the generation mechanisms,and influencing factors of the UBC were revealed.Global sensitivity analysis shows that the main roof hanging length(l_(2))and the spacing between the PPS(r)significantly impact the UBC.A novel design of the PPS and the coupling control technology were proposed and applied to reduce the UBC of the PPS in the adjacent longwall PRR.Monitor results showed no failure of the PPS at the test site,with the UBC(ζ)reduced to 1.1 consistent with the design value(1.15)basically,fully utilizing the collaborative LBP of the PPS.Finally,the maximum roof-to-floor convergence of the PRR was 234 mm,effectively controlling the stability of the surrounding rock of the PRR and ensuring the mining equipment recovery.

Microstructure and properties of laser cladding of 316L stainless steel on hydraulic support tube

In consideration of the special environmental conditions of coal equipment in mining, the seamless steel tube of hy-draulic prop made of 20^# carbon steel was taken as the substrate, and 316L stainless steel powder was used to clad the sub-strate by a fiber-coupled semiconductor laser. The microstructure of the cladding layer was determined by metalloscope. The hardness, wear resistance and corrosion resistance of the cladding layer were measured. The results show that metallurgy bind-ing interface between the cladding layer and the substrate is obtained without defects such as cracks and pores. The hardness of the cladding layer is much higher than that of the matrix, and the wear resistance and corrosion resistance are simultaneously better. According to the analysis, it is summarized that the improvement in performance of the cladding layer is closely related to the change of microstructure and the thermal effect in the cladding process. The maximum hardness occurs in the equiaxed zone, and with the grain coarsening, the hardness reduces simultaneously. In addition, the precipitated phase, hard particles and trace elements also have a great influence on the properties of the cladding layer, and they will prevent the surface from ab-rasion and reduce the plastic deformation of the matrix. It is verified that the 316L stainless steel is suitable for the 20^# steel in laser cladding repairing process. Since this study focused on coal machine equipment parts, it has certain practical significance for the repair of hydraulic equipment.

Structure optimal design research on backfill hydraulic support

Backfill hydraulic support is the key equipment in achieving coal mining and solid backfilling simultaneously in solid backfill mining technology.Based on the summary and analysis of main types,basic structural properties and filed application of backfill hydraulic support,this work has firstly proposed the basic principle of backfill hydraulic support optimization design and provided the method of optimal design of key structural components,like four-bar linkage,rear canopy and tamping structure;the method is further elaborated as changing hinging position of upper bar to optimize four-bar linkage,by lengthening or shortening the rear canopy to optimize length ratio of canopy;and by changing length and hinging position of tamping structure as well as suspension height of backfill scrape conveyor to realize optimization of tamping structure.On this basis,the process of optimal design of backfill hydraulic support is built.The optimal design case of ZC5200/14.5/30 six columns-four bar linkage used in 7203 W workface of Zhaizhen Coal Mine shows that the backfill properties like horizontal roof gap,vertical horizontal gap,tamping angle and tamping head gap are improved obviously through optimizing four-bar linkage,canopy length and tamping structure according to the optimal design method proposed in this work.

Hydraulic support crushed mechanism for the shallow seam mining face under the roadway pillars of room mining goaf

While the fully-mechanized longwall mining technology was employed in a shallow seam under a room mining goaf and overlained by thin bedrock and thick loose sands, the roadway pillars in the abandoned room mining goaf were in a stress-concentrated state, which may cause abnormal roof weighting, violent ground pressure behaviours, even roof fall and hydraulic support crushed(HSC) accidents. In this case,longwall mining safety and efficiency were seriously challenged. Based on the HSC accidents occurred during the longwall mining of 3-1-2 seam, which locates under the intersection zone of roadway pillars in the room mining goaf of 3-1-1 seam, this paper employed ground rock mechanics to analyse the overlying strata structure movement rules and presented the main influence factors and determination methods for the hydraulic support working resistance. The FLAC3 D software was used to simulate the overlying strata stress and plastic zone distribution characteristics. Field observation was implemented to contrastively analyse the hydraulic support working resistance distribution rules under the roadway pillars in strike direction, normal room mining goaf, roadway pillars in dip direction and intersection zone of roadway pillars. The results indicate that the key strata break along with rotations and reactions of the coal pillars deliver a larger concentrated load to the hydraulic support under intersection zone of roadway pillars than other conditions. The ‘‘overburden strata-key strata-roadway pillars-immediate roof" integrated load has exceeded the yield load that leads to HSC accidents. Findings in HSC mechanism provide a reasonable basis for shallow seam mining, and have important significance for the implementation of safe and efficient mining.

Nonlinear Static and Dynamic Stiffness Characteristics of Support Hydraulic System of TBM

Full-face hard rock tunnel boring machines(TBM)are essential equipment in highway and railway tunnel engineering construction.During the tunneling process,TBM have serious vibrations,which can damage some of its key components.The support system,an important part of TBM,is one path through which vibrational energy from the cutter head is transmitted.To reduce the vibration of support systems of TBM during the excavation process,based on the structural features of the support hydraulic system,a nonlinear dynamical model of support hydraulic systems of TBM is established.The influences of the component structure parameters and operating conditions parameters on the stiffness characteristics of the support hydraulic system are analyzed.The analysis results indicate that the static stiffness of the support hydraulic system consists of an increase stage,stable stage and decrease stage.The static stiffness value increases with an increase in the clearances.The pre-compression length of the spring in the relief valve a ects the range of the stable stage of the static stiffness,and it does not a ect the static stiffness value.The dynamic stiffness of the support hydraulic system consists of a U-shape and reverse U-shape.The bottom value of the U-shape increases with the amplitude and frequency of the external force acting on the cylinder body,however,the top value of the reverse U-shape remains constant.This study instructs how to design the support hydraulic system of TBM.

Dynamic impact experiment and response characteristics analysis for 1:2 reduced-scale model of hydraulic support

It is significant to research the impact resistance properties of hydraulic support due to its key support role in the fully mechanized mining face.However,it is difficult for the entire hydraulic support to implement the impact experiment underground and analyze the response characteristic.Therefore,a dynamic impact experiment for the entire hydraulic support was proposed in this paper,where a 1:2 reducedscale model of hydraulic support was designed and its response characteristics under dynamic impact load were analyzed.Firstly,a comprehensive monitoring scheme was proposed to achieve an effective monitoring for dynamic response of hydraulic support.Secondly,a multi-scale impact experiment was carried out for the entire hydraulic support and dynamic behaviors of hydraulic support under the multi-scale impact load were revealed by experimental data.Then a dynamic impact experiment of the entire hydraulic support was simulated in ADAMS with the same experiment conditions,and the experimental and simulation data were verified mutually.Finally,the characteristics of energy conversion and dissipation of the entire experiment system after impact were analyzed.The experiment results showed that the impact resistance properties of hydraulic support largely depended on the initial support conditions and different vertical rigidities affected energy distribution proportion of the entire support system.

Horizontal roof gap of backfill hydraulic support

For the backfill hydraulic support as the key equipment for achieving integration of backfilling and coal mining simultaneously in the practical process, its characteristics will directly influence the backfill body's compression ratio. Horizontal roof gap, as a key parameter of backfilling characteristics, may impact the backfilling effect from the aspects of control of roof subsidence in advance, support stress, backfilling process and the support design. Firstly, the reason why horizontal roof gap exists was analyzed and its definition, causes and connotation were introduced, then adopting the Pro/E 3D simulation software, three typical 3D entity models of backfill hydraulic supports were built, based on the influence of horizontal roof gap on backfilling effect, and influence rules of four factors, i.e. support height, suspension height, suspension angle and tamping angle, were emphatically analyzed on horizontal roof gap. The results indicate that, the four factors all have significant impacts on horizontal roof gap, but show differences in influence trend and degree, showing negative linear correlation, positive linear correlation, positive semi-parabolic correlation and negative semi-parabolic correlation, respectively. Four legs type is the most adaptive to the four factors, while six legs(II) type has the poorest adaptability, and the horizontal roof gap is small under large support height, small suspension height, small suspension angle and large tamping angle situation. By means of optimizing structure components and their positional relation and suspension height of backfill scrape conveyor in the process of support design and through controlling working face deployment, roof subsidence in advance, mining height and backfilling during engineering application, the horizontal roof gap is optimized. The research results can be served as theoretical basis for support design and guidance for backfill support to have better performance in backfilling.

VIRTUAL DESIGN OF A NEW TYPE OF HYDRAULIC SUPPORT

Using virtual reality to design a new type of hydraulic support is discussed.That is how to make use of the virtual design to develop coal mining machine in practice. Theadvantages of virtual design are studied and the simple virtual reality system is built. The 3Dparts and elements of hydraulic support are modeled with parametric design in CAD software, thenexported to VR environment, in which the virtual hydraulic support is assembled, operated andtested. With the method, the errors and faults of design can be fined easily, many improvements aremade and the new hydraulic support is developed successfully.

Mechanisms and Kinematics of Hydraulic Support for Top-Coal Caving

The structure and characteristic of new type of hydraulic support for top coal caving were discussed. The mechanism and kinematics of the hydraulic support were analyzed. The formulas were deduced to calculate the velocity and acceleration of top beam, shield beam, front and back legs, which give the solution to the design and research for hydraulic support.

The research of the evaluation system for the sealability of hydraulic supports and jacks＇ seals

In order to enhance the sealing quality and assemble efficiency of hydraulic supports, the evaluation system for the sealability of the hydraulic support and jack＇s seals was established through the testing and experimenting technology in respects, such as seals＇ dimensions, reasonable amounts of compression, sealability, life, resistance to pressure, etc. Through life detecting test of the seal, found the longest life seal ring under the same conditions, and through the reciprocating test of the hydraulic support, found the most appropriate amount of interference between the groove and the seal ring, thus, to decrease the leakage and extend the life span of the hydraulic support.

Longwall Top-Coal Caving in Thinner Thick-Seam and Research on Light Hydraulic Support

The application of light hydraulic support highlights the advantages of longwall top-coal caving (LTC) in thinner thick-seams (3. 0~ 5. 0 m). Considering the problems in practice, the developing of its new series will promote the mining of LTC with light hydraulic supports. Some relevant technical problems of the caving technology and the future of this series of supports are analyzed in this paper with several new opinions.

Computer-Aided Rapid Variant Design System for Hydraulic Support

The paper gives a detail analysis on the necessity of rapid hydraulic support design, and presents a computer-aided rapid variant design system for hydraulic support. The system integrates the type selection and embodiment design of hydraulic support. Case-based reasoning and rule-based reasoning are the main reasoning methods. Several crucial problems are discussed.

A soft-sensing model on hydraulic excavator's backhoe vibratory excavating resistance based on fuzzy support vector machine

In order to measure the backhoe vibratory excavating resistance of a hydraulic excavator fast and precisely,the influences of vibratory excavating depth,angle,vibratory frequency,amplitude,bucket inserting velocity and soil type on the vibratory excavating resistance were analyzed.Simulation analysis was carded out to establish the bucket inserting velocity,amplitude and vibratory frequency considered as secondary variables and excavating resistance as primary variable.A fttzzy membership function was introduced to improve the anti-noise capacity of support vector machine,which is a soft-sensing model on the hydraulic excavator＇s backhoe vibratory excavating resistance based on fuzzy support vector machine.The simulation result reveals that its maximum relative training and testing error are nearly 0.68% and-0.47%,respectively.It is concluded that the model has quite high modeling precision and generalization capacity,and it can measure the vibratory excavating resistance accurately,reliably and fast in an indirect way.

Optimization of Molten Salt Cleaning Process for Surface Roughness of Remanufactured 27SiMn Hydraulic Support Column

During molten salt cleaning of remanufactured 27SiMn hydraulic support column,oxidation occurs on the surface of metal substrate.This results in a change of the surface roughness of metal substrate after cleaning,which affects subsequent remanufacturing process.To decrease the effect is very important.This paper analyzed the oxidation mechanism of molten salt cleaning,explored the oxidation reaction that occurred during cleaning,and determined the key process parameters of cleaning that affecting oxidation reaction.By using central composite experimental design method and taking surface roughness variation of 27SiMn steel samples before and after molten salt cleaning as response variable to optimize the key process parameters,the optimal parameters of molten salt for cleaning remanufactured 27SiMn hydraulic support column could be obtained.The results show that the oxidation reaction of cleaning paint dirt can protect metal substrate from oxidation to a certain extent,and cleaning temperature and placement depth of metal substrate have a direct impact on the degree of oxidation reaction.When the cleaning temperature is 300℃and the distance between paint dirt and free surface of molten salt is 0.5 times the height of the parts,the surface roughness variation is minimal.Therefore,the cleaning quality will be improved under such parameters.

FLUID INDUCED HYDRAULIC SYSTEM VIBRATIONOF POWERED SUPPORT

Fluid and solid interaction analysis of hydraulic support under the coming pressure of roof rocks was presented. The mathematical model of the system was proposed and numerical studies by the character line method were carried out.

STUDY OF A FAULT DIAGNOSIS EXPERT SYSTEM FOR SYNTHETIC MINING SYSTEM HYDRAULIC SUPPORT

Fault diagnosis expert system for hydraulic support is studied.The system is achieved by Turbo prolong Language, it summaries the experience of the domain expert and sets up a fault tree, knowledge base is developed by a productive rule.According to the feature of diagnosis, the system selects forward non determination inferring and limited depth first search strategy.It can accomplish expert diagnosis of more than 50 kinds faults in hydraulic support.

改进YOLOv5s的采煤机滚筒与支架护帮板干涉状态智能识别

针对综采工作面液压支架护帮板处于未收回异常状态导致采煤机滚筒与护帮板干涉问题,提出一种改进YOLOv5s的采煤机滚筒与液压支架护帮板干涉状态智能识别方法。运用课题组前期提出的基于边界约束和非线性上下文正则化的去雾去尘方法对视频图像进行清晰化处理,提高综采工作面监控视频图像质量;对YOLOv5s模型进行改进,通过将YOLOv5s主干网络中的普通卷积Conv替换为分类效果更佳的Ghost卷积,减少了模型的参数数量,提高了模型识别速度,同时引入坐标注意力机制,提高了模型对护帮板和滚筒特征提取能力,从而提高模型识别精确率。运用软非极大值抑制算法(Soft-NMS)的锚框筛选方法,减少因护帮板重叠而发生漏检问题。针对采煤机滚筒与液压支架护帮板干涉状态判定问题,提出液压支架护帮板与采煤机滚筒锚框重合度的判定方法。运用本文改进YOLOv5s模型与YOLOv5s、YOLOv3-tiny模型进行对比分析,结果表明:本文方法与原模型相比的识别精确率提高了约8.1%,GFLOPs降低1.86倍;mAP@.5达到97.2%、平均识别速度为检测时间为5.9 ms。运用本文方法对煤矿实际综采工作面采煤机滚筒与液压支架护帮板视频图像进行干涉状态识别试验验证,结果表明:对采煤机滚筒与液压支架护帮板干涉状态识别准确率为96%。

基于差分非平稳Transformer的液压支架立柱压力预测

液压支架立柱压力预测是回采工艺决策的重要依据,也是确保围岩稳定的基础信息之一。然而,液压支架立柱压力虽然具有一定的规律性,却无法用简单的数学模型进行预测;且在回采过程中,支架不接顶、顶板破碎、传感器检测误差等带来大量的随机噪声,使得压力数据劣化为非平稳时间序列,给压力的预测带来的很大的困难。本文在Transformer基础上,提出一种差分非平稳Transformer模型,在Transformer的编码器和解码器中分别引入差分归一化和反归一化操作,以提升序列的平稳性。同时,在Transformer中采用去平稳注意力机制,计算序列元素之间的关联关系,以增强模型的预测能力。在真实的煤矿支架立柱数据集上的对比实验表明,本文提出的差分非平稳Transformer的预测效果达到0.674,表现明显优于LSTM、Transformer和非平稳Transformer模型。

基于PSO−ELM的综采工作面液压支架姿态监测方法

针对基于惯性测量单元的液压支架姿态解算方法会产生累计误差、校正结果不准确的问题,提出一种基于粒子群优化(PSO)−极限学习机(ELM)的综采工作面液压支架姿态监测方法。以液压支架顶梁俯仰角为监测对象,采用倾角传感器和陀螺仪采集液压支架顶梁支护姿态实时信息,对采集到的数据进行预处理,将处理后的数据输入PSO−ELM误差补偿模型中,得到解算误差预测值;同时通过卡尔曼滤波融合进行液压支架姿态解算,得到解算值;再用误差预测值对解算值进行误差补偿,从而求得更加准确的顶梁支护姿态数据。该方法只考虑加速度和角速度数据与解算误差的关系,不依赖具体的物理模型,可有效降低姿态解算累计误差。实验结果表明:液压支架顶梁俯仰角平均绝对误差由补偿前的1.4208°减少到0.0580°,且误差曲线具有良好的收敛性,验证了所提方法可持续稳定地监测液压支架的支护姿态。

基于LSTM-Informer模型的液压支架压力时空多步长预测

目前多步液压支架压力预测大多为单步液压支架压力的累计预测,单步累计次数越多,累计误差就越大,影响预测精度。针对该问题,提出了一种基于长短时记忆(LSTM)-Informer模型的液压支架压力时空多步长预测方法。采用卡尔曼滤波消除液压支架压力数据中的振动噪声后,在工作面端部和中部各选取相邻的5台液压支架压力数据建立2个时空数据集(数据集1和数据集2),并对时空数据进行标准化预处理。将时空数据输入LSTM模型提取时空特征,并将提取的时空特征输入Informer模型的编码器,经过位置编码后利用多头概率稀疏自注意力来关注压力序列的变化特征,经过最大池化和一维卷积消除最终输出特征图的冗余组合。利用多头概率稀疏自注意力来关注压力序列的变化特征,将Informer模型的解码器改为全连接层,得到液压支架压力的预测结果。实验结果表明:与基于门控循环单元(GRU)、LSTM和Informer模型的预测方法相比,基于LSTM-Informer模型的预测方法在预测6,12,24步长液压支架压力时的均方根误差(RMSE)和平均绝对误差(MAE)均最小;其中基于数据集1预测的6步长液压支架压力的RMSE分别降低了41.63%,49.74%,11.85%,MAE分别降低了41.75%,50.00%,12.00%;基于数据集2预测的6步长液压支架压力的RMSE分别降低了48.15%,59.86%,19.88%,MAE分别降低了49.87%,54.90%,13.16%。