Instability mechanism of mining roadway passing through fault at different angles in kilometre-deep mine and control measures of roof cutting and NPR cables

The angle α between the fault strike and the axial direction of the roadway produces different damage characteristics. In this paper, the research methodology includes theoretical analyses, numerical simulations and field experiments in the context of the Daqiang coal mine located in Shenyang, China. The stability control countermeasure of "pre-splitting cutting roof + NPR anchor cable"(PSCR-NPR) is simultaneously proposed. According to the different deformation characteristics of the roadway, the faults are innovatively classified into three types, with α of type I being 0°-30°, α of type II being 30°-60°, and α of type III being 60°-90°. The full-cycle stress evolution paths during mining roadway traverses across different types of faults are investigated by numerical simulation. Different pinch angles α lead to high stress concentration areas at different locations in the surrounding rock. The non-uniform stress field formed in the shallow surrounding rock is an important reason for the instability of the roadway. The pre-cracked cut top shifted the high stress region to the deep rock mass and formed a low stress region in the shallow rock mass. The high prestressing NPR anchor cable transforms the non-uniform stress field of the shallow surrounding rock into a uniform stress field. PSCR-NPR is applied in the fault-through roadway of Daqiang mine. The low stress area of the surrounding rock was enlarged by 3-7 times, and the cumulative convergence was reduced by 45%-50%. It provides a reference for the stability control of the deep fault-through mining roadway.

Stability control measures for roof cutting and NPR supporting of mining roadways in fault areas of kilometre-deep coal mine

The study focuses on the stability control measures for mining roadways in fault zones of deep mines,using Daqiang Coal Mine as a case study.The control system under consideration,referred to as"pre-splitting cutting roof+NPR anchor cable"(PSCR-NPR),is subjected to scrutiny through theoretical analysis,numerical modelling,and field trials.Furthermore,a comprehensive analysis is undertaken to evaluate the stability control mechanism of this particular technology.The study provides evidence that the utilization of deep-hole directional energy-concentrated blasting facilitates the attainment of directional roof cutting in roadways.The aforementioned procedure leads to the formation of a uniform structural surface on the roof of the roadway and causes modifications in the surrounding geological formation.The examination of the lateral abutment pressure and shear stress distribution,both prior to and subsequent to roof cutting,indicates that the implementation of pre-splitting techniques leads to a noteworthy reduction in pressure.The proposition of incorporating the safety factor Q for roof cutting height is suggested as a method to augment comprehension of the pressure relief phenomenon in the field of engineering.The analysis of numerical simulation has indicated that the optimal pressure relief effect of a mining roadway in a fault area is attained when the value of Q is 1.8.The NPR anchor cable exhibits noteworthy characteristics,including a high level of prestress,continuous resistance,and substantial deformation.After the excavation of the roadway,a notable reduction in radial stress occurs,leading to the reinstatement of the three-phase stress state in the surrounding rock.This restoration is attributed to the substantial prestress exerted on the radial stress.The termination point of the NPR anchor cable is strategically positioned within a stable rock formation,allowing for the utilization of the mechanical characteristics of the deep stable rock mass.This positioning serves to improve the load-bearing capacity of the surrounding rock.The mining roadway within the fault region of Daqiang Coal Mine is outfitted with the PSCR-NPR technology.The drop in shear stress experienced by the rock surrounding the roadway is estimated to be around 30%,whilst the low-stress region of the mining roadway extends by a factor of approximately 5.5.The magnitude of surface displacement convergence experiences a decrease of approximately 45%-50%.The study’s findings provide useful insights regarding the stable of mining roadway in characterized by fault zones.

Evaluation of roof cutting by directionally single cracking technique in automatic roadway formation for thick coal seam mining

Automatic roadway formation by roof cutting is a sustainable nonpillar mining method that has the potential to increase coal recovery,reduce roadway excavation and improve mining safety.In this method,roof cutting is the key process for stress relief,which significantly affects the stability of the formed roadway.This paper presents a directionally single cracking(DSC)technique for roof cutting with considerations of rock properties.The mechanism of the DSC technique was investi-gated by explicit finite element analyses.The DSC technique and roof cutting parameters were evaluated by discrete element simulation and field experiment.On this basis,the optimized DSC technique was tested in the field.The results indicate that the DSC technique could effectively control the blast-induced stress distribution and crack propagation in the roof rock,thus,achieve directionally single cracking on the roadway roof.The DsC technique for roof cutting with optimized parameters could effectively reduce the deformation and improve the stability of the formed roadway.Field engineering application verified the feasibility and effectiveness of the evaluated DSC technique for roof cutting.

Investigation of a non-explosive directional roof cutting technology for self-formed roadway

Traditional explosives have characteristics of high risk,large vibration,and poor directional fracturing.Consequently,an instantaneous expander with a single crack surface(IESCS),which is a novel nonexplosive directional rock-breaking technique,has been developed.The directional roof-cutting mechanism of the IESCS method,driven by high-pressure gas,was theoretically analyzed.Laboratory experiments and numerical simulations proved the directional slitting effect of the IESCS method to be excellent.Compared with shaped-charge blasting,the charge of IESCS was reduced by 8.9%,but the crack rate increased by 9%in field tests.After IESCS pre-splitting,the roof directionally collapsed along the cutting line,and the gangue filled the goaf.Moreover,the directional roof cutting by the IESCS could decrease roadway stress.The average pressure of hydraulic supports on the cutting side of the roof was 31%lower than that on the non-cutting side of the roof after pre-splitting.After the self-formed roadway constructed by the IESCS was stabilized,the final relative displacement of the roof and floor was 157.3 mm,meeting the required standard of the next working face.Thus,the IESCS was effectively applied to directional roof pre-splitting.The results demonstrate the promising potential of IESCS in the mining and geotechnical fields.

Fixed-length roof cutting with vertical hydraulic fracture based on the stress shadow effect:A case study

Pre-driven longwall retracement roadway(PLRR)is commonly used in large mine shaft.The support crushing disasters occur frequently during the retracement,and roof management is necessary.Taking the 31107 panel as research background,the roof breaking structure of PLRR is analyzed.It is concluded that the roof cutting with vertical hydraulic fracture(HF)at a specified position,that is,fixed-length roof cutting,can reduce support load and keep immediate roof intact.The extended finite element method(XFEM)is applied to simulate hydraulic fracturing.The results show that both the axial and transverse hydraulic fracturing cannot effectively create vertical HFs.Therefore,a novel construction method of vertical HF based on the stress shadow effect(SSE)is proposed.The stress reversal region and HF orientation caused by the prefabricated hydraulic fracture(PF)are verified in simulation.The sub-vertical HFs are obtained between two PFs,the vertical extension range of which is much larger than that of directional hydraulic fracturing.The new construction method was used to determine the field plan for fixed-length roof cutting.The roof formed a stable suspended structure and deformation of the main PLRR was improved after hydraulic fracturing.

短横轴截割机器人直墙拱形巷道自动成形控制方法

针对掘进机在直墙拱形巷道掘进过程中存在定位难、截割效率低、成形质量差等问题,提出一种短横轴截割机器人及其自动成形控制方法。首先设计了串联式短横轴截割机器人结构,构建了短横轴截割机器人运动学模型,建立了截割臂升降油缸、滑移油缸及回转油缸伸缩量与截割头末端位姿的数学关系,提出了短横轴截割机器人直墙拱形巷道自动成形控制方法;其次研究分析了短横轴截割机器人截割头包络空间与直墙半圆拱形巷道空间耦合关系,确定了截割过程中截割轨迹关键点位置,提出了基于截割轨迹关键点的“弓”型截割轨迹规划方法;然后根据建立的短横轴截割机器人运动学模型,求解截割头在跟踪截割轨迹的过程中运动控制量和截割、修帮、扫底3个任务各个关节控制时序;最后以模糊PID为例,建立了短横轴截割机器人自动成形控制方法,利用Adams软件对短横轴截割机器人进行截割运动仿真试验。结果表明:利用“弓”型截割轨迹规划方法能够完成直墙拱形巷道的截割轨迹规划,控制截割头对截割轨道进行跟踪控制,实现了直墙拱形巷道断面的自动成形截割,截割成形的巷道最大欠挖量为48 mm,最大超挖量为21 mm,满足煤矿巷道成形质量要求。研究得出短横轴截割机器人可在沿巷道中线不左右移机的情况下,高效率、高质量地完成直墙拱形巷道断面自动成形截割任务。

数字孪生驱动的巷道自动成形截割虚拟调试方法研究

针对目前巷道自动成形截割控制调试周期长、调试成本大、安全风险大、成形质量难以评价等问题,提出了一种数字孪生驱动的巷道自动成形截割虚拟调试方法。采用基于即时外观建图(RTAP−MAP)技术重建巷道三维环境,构建掘进机控制系统模型,形成虚拟调试环境,并利用虚拟传感器技术实现物理空间到虚拟环境状态的精准映射。针对难以量化评估断面成形质量的问题,确立了巷道自动成形截割性能评价方法,以断面成形截割控制过程在数据传输中心的记录为基础,主要对断面成形精度、截割效率与油缸开关次数、硬岩切割调整、超挖欠挖4个评价指标进行计算,从而为深度学习算法的迭代优化提供精准反馈信号,并提出了一种融合强化学习的自动截割控制策略,以提高自动化作业的适应性和精确度。为验证该虚拟调试方法的有效性和准确性,搭建了掘进机自动控制实验平台,并将虚拟调试系统应用于掘进巷道成形截割自动控制程序中。虚拟仿真结果表明:①被调试软件在控制关键点位处的X,Y,Z轴定位误差的最大值分别为74.8,72.93,123.67 mm,说明虚拟调试方法的定位精度达到性能要求。②虚拟样机与物理样机轨迹基本一致,说明该调试方法实现了对物理空间的映射。应用结果表明:①强化学习控制器在虚拟掘进测试中适应了复杂环境,将虚拟传感器输入有效转换为精准控制指令,验证了模拟−现实迁移训练的可行性。通过处理掘进精度和避免超欠挖的实时反馈,控制器学习并优化了策略。②优化后的断面成形截割控制性能得到了提升,根据数据库中控制量时间戳的记录,用时126 s,较优化前耗时减少了8 s。③优化后截割部末端轨迹跟踪最大误差为6.0 mm,较优化前降低了0.3 mm,避免了截割轨迹抖动导致的欠挖,同时使得轨迹和断面更加平滑。

硬岩顶板切顶留巷围岩变形分区补强控制研究

【目的】森达源煤矿传统的宽煤柱开采方式导致采掘接续紧张,并引发严重的围岩变形问题。切顶留巷技术可优化巷道支护条件,提高采煤效率,促进煤矿高效安全生产。【方法】以1号煤层的10101工作面为研究对象,运用FLAC 3D数值模拟软件,深入探究了切顶高度、切顶角度、注浆加固深度对巷道掘进、预裂切顶和切顶留巷过程中煤帮内部、采空区及顶板应力变形特性的影响。确定出最佳切顶留巷方案。在此基础上,进一步模拟分析工作面前后不同区域的围岩受力变形情况。提出回采工作面前方0~30 m内为超前补强区,采取“高预应力锚索+单体配合铰接顶梁”的联合支护。后方0~100 m内为滞后补强区,采用“工字钢+单体支柱”联合支护,同时对矸石帮实施注浆加固。通过工程应用验证了区分补强控制变形措施的有效性。【结果】结果显示:最佳切顶留巷方案为切顶高度6 m,切顶角度15°,矸石帮注浆深度1 m。此方案下,10101工作面的巷道顶底板的最终变形量为155 mm,两帮的为84 mm,均符合矿井使用要求,验证了切顶留巷技术具有良好效果。【结论】结果表明:切顶留巷技术能有效解决传统宽煤柱开采方式中存在的围岩变形问题。然而,该技术的实施受切顶高度、切顶角度和矸石帮注浆深度等因素的影响较大,需结合数值模拟和现场状况进行具体确定。总体上,切顶留巷技术和分区补强控制措施对围岩变形的控制效果显著,为类似条件下的煤矿开采提供了宝贵的经验借鉴,因而具有广阔的应用前景。

大采高综采工作面切顶留巷矸石帮变形控制技术研究

为解决厚煤层大采高综采工作面切顶留巷矸石帮围岩控制难题,首先利用理论分析建立了不同挡矸支护条件下矸石帮位移变化的力学公式,以此为基础提出矸石帮变形控制双策略,减弱矸石帮变形压力和增强矸石帮的抗变形能力;其次利用现场实验设计两种类别共4组挡矸支护方案,探讨不同支护方案的矸石帮控制效果,验证理论研究成果。结果表明:①增强矸石帮侧顶板支护强度,能减弱矸石帮变形压力;②增架卡兰个数、增加卡兰预紧力、增加卡兰个数、增强U型钢之间的摩擦力等能增加U型钢滑移初始滑移应力,增强矸石帮的抗变形能力;③挡矸支护控制效果为:2副卡兰+单体支柱<2副卡兰+单元支架<2副卡兰+单元支架+呛柱<3副卡兰+单元支架。该研究可为同类条件下切顶留巷矸石帮变形控制提供参考。

坚硬顶板切顶卸压技术对巷道围岩变形规律影响

针对特厚煤层坚硬顶板、宽煤柱条件下临空巷道面临的高围岩应力、大变形等问题,以老石旦煤矿16403综放工作面为工程研究背景,从宽煤柱顶板侧向破断结构角度对临空巷道大变形的影响因素进行了理论分析,采用数值模拟方法研究了对16402运输巷实施不同切顶卸压方案时,临近采空区的16403回风巷侧向顶板采动应力传递规律,并在现场施工水力压裂钻孔进行切顶卸压,实现临空巷道围岩变形控制。研究结果表明:“低位坚硬岩层悬臂梁+高位坚硬岩层砌体梁”破断结构是特厚煤层宽煤柱临空巷道大变形的主要原因,可采用切顶卸压技术破坏宽煤柱顶板侧向破断结构来控制临空巷道围岩大变形;切顶角变化可使关键块B长度发生改变,切顶角越大,则关键块B长度越小,临空侧顶板载荷向煤柱传递的程度越弱,临空巷道围岩承受的采动应力越小,切顶角为100°时临空巷道围岩垂直应力与变形量最小;在16402运输巷以切顶角100°施工水力压裂钻孔后,16403回风巷顶底板变形量较未实施切顶卸压的16402回风巷减小86.5%,两帮变形量减小87.1%,临空巷道围岩稳定性得到极大提高。

基于机器视觉的煤尘环境下掘进空间煤岩界面感知与精准识别

巷道掘进过程中煤岩识别技术是掘进机截割头自动调整的核心,同样是制约矿山智能化建设的关键难题之一。针对当前采掘失衡,掘进工作面缺乏成熟有效的煤岩识别方案,现有基于图像的煤岩识别模型存在分割精度差、无法灵活部署等问题,提出一种应用在掘进工作面下基于图像分割的煤岩截割界面感知与精准识别方法。该方法结合掘进工作面实际截割情况,采用Mobile-NetV2特征提取网络作为DeepLabV3+的主干网络,使模型更好地兼顾分割精度和模型复杂度;将空洞空间卷积池化金字塔模块输出的高级特征进行通道注意力(SE)操作,分配通道权重以强化对重点特征信息的训练;在主干网络输出的浅层特征引入通道空间注意力(CA)机制,使浅层特征图中的低级表征信息加权,从而设计出融合双注意力机制于DeepLabV3+的煤岩截割界面识别模型。同时搭建煤尘环境下煤岩识别实验平台模拟掘进机截割后形成的煤岩截割面,研发巷道掘进过程中煤岩截割界面采集方法,并以实际矿井的掘进工作面为工程背景,验证该煤岩识别模型的分割精度以及实际应用性。研究结果表明:SE-CA-DeepLabV3+模型的平均交并比和平均像素精度分别为97.15%和98.51%,相较于其他模型具有更优的分割性能。将所建立模型对来自陕北试验矿井掘进工作面的原始煤岩图像进行验证,平均误差为0.7%,每秒传输帧数为43 fps,满足井下现场应用部署条件。

厚煤层动压巷道切顶护巷关键参数研究

针对厚煤层切顶护巷围岩矿压显现较为剧烈的工程问题,采用理论分析、FLAC3D数值模拟和巷道围岩变形现场试验,对韩城矿区桑树坪二号井厚煤层切顶卸压护巷关键参数进行探究,得出:切顶导致基本顶原有应力传递路径发生改变,使得压力转移到采空区,从而减轻采空区的侧向实体围岩应力,围岩应力越发均匀缓和;通过理论分析和数值模拟的方法,对切顶高度为10.5、12.5、14.5、16.5 m及切顶角度为55°、65°、75°、85°的巷道围岩应力及其分布进行了分析,结果表明:最佳切顶高度14.5 m和切顶角度75°不仅能有效切断采空区顶板岩层与巷道之间的应力传递路径,迫使应力集中区域向实体煤深处转移,还能使得顶板岩层在工作面回采后及时垮落并充填至采空区,进而改善巷道围岩应力环境;通过现场试验对3308工作面二号回风平巷进行了表面位移观测,巷道围岩变形量小,护巷效果良好。

托顶煤切顶留巷围岩控制技术研究

为了解决托顶煤巷道围岩变形难以控制的问题,运用理论分析、离散元数值模拟及现场工业试验相结合的方法对义棠煤业100602工作面切顶成巷围岩控制技术进行研究,分析了不同切顶高度、采高对留巷围岩变形影响规律。研究发现,适当增加切顶高度并降低采高有利于巷道围岩稳定,并确定开采技术参数为切顶高度24 m、采高6 m。现场监测结果显示,在合理的支护策略及开采工艺参数下,托顶煤切顶留巷围岩变形控制效果良好。

综采工作面超前巷道变形机制及围岩控制技术研究

针对采煤工作面超前巷道变形量大等问题,研究了采煤工作面端部覆岩运动特性对超前巷道变形的影响,分析了超前巷道切顶卸压机理,确定了合理的切顶参数,进行了现场试验。结果表明:工作面超前巷道的变形的根本原因是工作面推进过程中弧形三角板在工作面推进方向和倾斜方向下沉运动导致其重量及其荷载作用在巷道顶板造成的,并在此过程引起超前支承压力和侧向支承压力的集中。有效切断回采巷道上方顶板与工作面顶板的联动效应后,超前巷道替代了单体架棚支护,超前巷道顶底板累计变形量和两帮累计移近量分别为未切顶的1/5和1/3。

坚硬顶板高压磨料射流侧向切顶煤柱卸荷技术研究

针对坚硬顶板下临空巷道存在的高应力、大变形、难支护等问题,分析了磨料射流能量分布情况,研究了磨料颗粒及高压水射流的冲击破岩作用。基于“砌体梁”原理,建立不同岩性条件下的岩层周期破断力学模型,研究了巷道侧向切顶条件下上覆岩层断裂情况,采用数值模拟分析切顶前后煤柱应力变化情况,提出了磨料射流侧向切顶煤柱卸荷技术。现场试验结果表明,采用磨料射流切顶后巷道高度变形量减小38.7%,宽度变形量减小45.8%,巷道变形得到有效控制。同时,切顶后每日最大总能量降低85.5%,平均每日总能量降低82.6%。验证了磨料射流侧向切顶对坚硬顶板的弱化效果,为坚硬顶板弱化治理提供了一种新的技术手段。

Z形工作面切顶留巷端头液压支架的研制

针对董东煤矿TC10工作面Z形条带开采工作面切顶留巷,研发了一种具有端头支护、巷道支护、切顶留巷、自移功能的端头支架,可布置在机尾处用于巷道支护和切顶留巷,可实现在工作面设备连续推进5个步距时架后巷道棚顶1次,减轻了劳动强度,提高了工作面采煤效率。

煤巷快速掘进改进工艺研究

针对古城煤矿现有掘进切割工艺,介绍了1种煤巷快速掘进改进工艺设计方案。该方案以原掘进切割工艺的具体情况为基础,结合煤矿领域现有掘进技术水平,设计出了多种不同的掘进切割方案,然后利用有限元分析软件分别对各种方案在实际中的应用效果进行模拟分析,并通过对比模拟分析结果,以此确定出最终的掘进切割方案。应用该改进工艺,不仅可以提升煤巷掘进速度,而且还可以提高井下作业的安全性,具有一定的应用价值。

临空巷道二氧化碳致裂切顶卸压技术应用研究

针对坚硬顶板临空巷道强矿压显现问题,以晋能控股煤业集团有限公司马脊梁煤矿为工程背景,运用理论分析、数值模拟方法进行了临空巷道二氧化碳致裂切顶卸压技术应用研究,并成功完成现场工业性试验。结果表明:二氧化碳致裂切顶卸压技术能够降低应力峰值,应力集中远离巷帮,缓解矿压显现现象,切顶高度和切顶角度对巷道围岩控制有显著影响,切顶高度越大卸压效果越好,但当切顶高度达到一定程度后,继续增加切顶高度对应力降低影响不甚明显;切顶角度大时煤柱内的应力显著降低,切顶角度小时更利于优化巷道附近应力环境;马脊梁煤矿5015巷应用二氧化碳致裂技术切顶卸压,顶底板移近量、两帮变形量、支承压力峰值较未切顶时分别降低22.6%、28.7%、21.8%,显著改善了巷道的应力环境,减小了围岩变形量,有助于解决强矿压显现问题。

深井切眼巷道爆破切顶留巷围岩控制技术研究

预裂爆破切顶留巷技术是现今煤矿开采中实现高效开采的重要手段,切顶效果的好坏直接影响到留巷的安全性和稳定性,而切眼巷道处的围岩情况与控制技术也有其不同点。鉴于此,本文针对朱集西煤矿13402工作面切眼巷道切顶留巷相关问题,从理论分析和数值模拟的角度分析了传统方式留巷和切顶留巷两种技术的差别性,阐明了切顶留巷技术的优越性。根据现场情况,针对性地提出了切眼巷道顶板“锚索补强支护+爆破切顶”,实体煤帮“锚杆索强力支护”、采空区侧“U型钢+挡矸支架护帮+锚杆补强”的围岩控制方案,并且对锚杆索参数、爆破深度和角度、装药结构等参数进行了设计。方案实施后,切眼巷道留巷效果良好,稳定后留巷的顶板下沉量约为225mm,实体煤帮变形量约为150mm,保证了下工作面的安全回采。

基于数字孪生技术的煤矿掘进机自动截割方法研究

为了解决目前掘进工作面设备自动化控制存在的缺乏可视化人机交互控制、缺乏掘进工作面数字孪生动态建模、缺乏巷道模型与掘进机定位导航系统融合的问题,提出一种基于三维数字孪生技术的煤矿掘进机自动截割方法;该方法利用三维数字孪生技术的巷道模型生成截割模板,实现掘进机对预设截割断面的自动化截割,可达到人工远距离、可视化控制掘进机安全自动作业的目的。介绍了数字化巷道和掘进机模型的构建方法以及数据驱动逻辑,并对掘进机自动截割控制方法进行了详细阐述。结果表明,该方法避免了粉尘等对掘进机自动化截割的影响,降低了人员现场作业风险和劳动强度,解决了掘进机远程截割精确度低、巷道断面成型质量差等问题。