电牵引采煤机分布式控制系统的研究与开发.pdf

工程硕士学位论文 电牵引采煤机分布式控制系统的研究与开发 Research and Development of Distributed Control System for Electric Haulage Shearer 作 者王雪松 导 师张建文教授 中国矿业大学 二〇二〇年六月 学位论文使用授权声明 学位论文使用授权声明 本人完全了解中国矿业大学有关保留、使用学位论文的规定，同意本人所撰 写的学位论文的使用授权按照学校的管理规定处理 作为申请学位的条件之一， 学位论文著作权拥有者须授权所在学校拥有学位 论文的部分使用权，即①学校档案馆和图书馆有权保留学位论文的纸质版和电 子版，可以使用影印、缩印或扫描等复制手段保存和汇编学位论文；②为教学和 科研目的，学校档案馆和图书馆可以将公开的学位论文作为资料在档案馆、图书 馆等场所或在校园网上供校内师生阅读、浏览。另外，根据有关法规，同意中国 国家图书馆保存研究生学位论文。 （保密的学位论文在解密后适用本授权书）。 作者签名 导师签名 年 月 日 年 月 日 中图分类号 TP273 学校代码 10290 UDC 621.3 密 级 公开 中国矿业大学 工程硕士专业学位论文 电牵引采煤机分布式控制系统的研究与开发 Research and Development of Distributed Control System for Electric Haulage Shearer 作 者 王雪松 导 师 张建文 教授 申请学位 工程硕士学位 培养单位 中国矿业大学 学科专业 控制工程 研究方向 煤机自动化 答辩委员会主席 程玉虎 评 阅 人 盲审 二○二○年六月 致谢 致谢 本论文是在导师张建文教授的悉心指导下完成的， 字里行间无不凝聚着导师 的智慧和心血。即使工作忙碌，导师也会抽时间与我们讨论论文，导师对学术一 丝不苟、严谨认真的治学态度深深地感染着我，激励着我。在准备论文期间，在 论文选题及撰写修改定稿等方面，导师给予细致入微的指导和启发。导师不仅是 学习中的良师，也是生活中的益友。每当感到迷茫彷徨之时，导师常常以他的亲 身经历为我们解疑答惑，用他的生活经验为我们指明方向。在学习上他对学生严 格要求，在生活中又极具亲和力，常常以朋友的方式与我们沟通交流，关心我们 的学习生活。在此对我的导师表达诚挚的敬意与谢意。 本论文的顺利完成， 得益于中国矿业大学信息与控制工程学院的老师和同学 们的关心和指导，在此表示衷心感谢 感谢太重煤机有限公司各位领导和同事对我的支持和帮助； 感谢太重煤机有限公司电气所全体开发人员车间和井下调试现场的辛劳付 出； 感谢中国矿业大学研究生院各位领导和老师对我的支持和帮助； 特别感谢中国矿业大学机电工程学院王世博教授对我的支持和帮助； 深深感谢父母的养育之恩， 漫漫求学路， 是您们用辛勤的劳动默默支持着我。 最后，衷心感谢在百忙之中评阅本文的各位专家，并给予宝贵的指导。在此 谨向各位专家和学者表示深深的谢意 I 摘摘 要要 随着煤炭智能开采从概念逐步且越来越富有内涵地走向工程实践， 作为其中 最为关键的开采装备采煤机也必须具备相应的智能化功能。 本文立足于作者 的工作岗位，结合太重煤机有限公司（以下简称太矿）智能开采装备研发规划， 对电牵引采煤机新一代分布式控制系统进行了深入系统的研究和实用产品的开 发。 首先，根据煤炭智能开采对采煤机的智能化要求，结合太矿采煤机及其控制 系统的发展历史、现有水平，以及应对未来智能开采时代的煤机发展战略，对标 国际先进水平， 制定了新一代电牵引采煤机分布式控制系统的整体架构和功能模 块构成采用 32 位主、从控制器（主控制器型号 DX-M3530，从控制器型号 DX-M302）、CAN 总线通讯方式的分布式控制模式；将整个控制系统按照功能 划分为主控制单元、高压测控单元、本安测控单元、无线 4G 信号转换模块、本 安信号采集模块、传感器单元等，并进行了主控制器的开发及检测检验。 第二，研发了分布式电控系统中主要监控模块，用于监测 8 路 PT100 温度 信号、三轴倾角、环境温湿度等。从该分布式模块的功能需求入手，分析并设计 了该模块的硬件电路，具体包括输入、输出量接口模块、电源模块、MCU 控 制部分、PT100 检测部分、CAN 通信部分、环境温湿度检测、倾角检测等，并 进行了可靠性测试设计。 第三，研究了采煤机状态监测与故障诊断系统并加以实现。状态监测除了常 规的电机温度、电流、牵引速度、角度等检测量以外，还通过安装旋转编码器、 压力、温度、振动、电缆张力等传感器实现了太矿采煤机更加全面的工况监测， 首次实现了太矿采煤机拖曳电缆的张力监测， 增强了采煤机机载预警与故障提示 功能，故障代码达到了 81 个；通过新研发的机载数据记录仪，可采集、存储采 煤机的 110 种状态数据，数据记录可长达 90 天、约 90 亿条记录；井下实时监测 的采煤机通讯状态、关键部位温度、压力及流量值、摇臂角度、煤机位置、记忆 截割等数据， 通过机载无线通信单元和防爆天线经矿井环网传输至太矿采煤机云 端远程运维中心， 为后期实现采煤机远程信息融合故障诊断和预测预警奠定了基 础。 第四，主持设计的基于分布式电控系统的采煤机智能化功能实现突破首次 实现了摇臂高度自动调节、牵引速度自动调节和基于 TD-LTE 制式的 4G 采煤机 信息无线传输等功能，显著提升了采煤机的智能化水平。 关键词关键词分布式控制；电牵引采煤机；智能化；CAN 总线；32 位控制器 II Abstract As the intelligent mining of coal moves from concept to engineering practice gradually and more intensively, as one of the most critical mining equipment, the coal mining machine must also have corresponding intelligent functions. Based on the authors job position, this article has carried out in-depth systematic research and practical product development on the new generation of distributed control system of electric haulage shearer in combination with the research and development plan of intelligent mining equipment of Taizhong Coal Machinery Co., Ltd. hereinafter referred to as Taikuang . First of all, according to the intelligent requirements of coal mining on coal mining machine, combined with the development history and existing level of Taiku coal mining machine and its control system, as well as the development strategy of coal mining machine in the future era of intelligent mining, benchmark the international advanced level Developed the overall architecture and functional module composition of the distributed control system of the new generation electric haulage shearer 32-bit master and slave controllers master controller model DX-M3530, slave controller model DX-M302, CAN bus Distributed control mode of communication ; divides the entire control system into main control unit, high voltage measurement and control unit, intrinsically safe measurement and control unit, wireless 4G signal conversion module, intrinsically safe signal acquisition module, sensor unit, etc. according to function device development and inspection. Second, the main monitoring module in the distributed electronic control system was developed to monitor the 8-channel PT100 temperature signal, three-axis tilt angle, ambient temperature and humidity, etc. Starting from the functional requirements of the distributed module, the hardware circuit of the module is analyzed and designed, including and output interface module, power supply module, MCU control part, PT100 detection part, CAN communication part, ambient temperature and humidity detection, Inclination detection, etc., and conducted reliability test design. Third, the status monitoring and fault diagnosis system of the shearer is studied and implemented. In addition to the conventional motor temperature, current, haulage speed, angle and other detection quantities, condition monitoring has also achieved a more comprehensive monitoring of the working conditions of the Taikuang coal III mining machine by installing sensors such as rotary encoders, pressure, temperature, vibration, cable tension, For the first time, the tension monitoring of the tow cable of the coal mining machine in Taikuang has been realized, and the functions of the on-board early warning and fault prompting of the coal mining machine have been enhanced. The number of fault codes has reached 81; through the newly developed airborne data recorder, the coal mining can be collected and stored 110 kinds of status data of the machine, and the data record can be up to 90 days, about 9 billion records; the real-time monitoring of the coal miners communication status, key parts temperature, pressure and flow value, rocker angle, coal machine position, memory interception The data such as cutting is transmitted to the cloud remote operation and maintenance center of the coal mining machine of Taikuang Coal Mine through the airborne wireless communication unit and explosion-proof antenna through the mine ring network, which lays the foundation for the future realization of remote diagnosis of coal miners remote ination fusion fault diagnosis and prediction and early warning. Fourthly, the intelligent function of the shearer based on the distributed electronic control system designed by the host has achieved breakthroughs for the first time, automatic adjustment of the height of the rocker arm, automatic adjustment of the haulage speed and wireless transmission of 4G shearer ination based on the TD-LTE system have been achieved The function has significantly improved the intelligence level of the shearer. Keywords distributed control; electric haulage shearer; intelligent; CAN bus; 32-bit controller. IV 目目 录录 摘摘 要要............................................................................................................................ I 目目 录录......................................................................................................................... IV 图清单图清单...................................................................................................................... VIII 表清单表清单...................................................................................................................... XIII 1 绪论绪论............................................................................................................................ 1 1.1 世界电牵引采煤机发展概述 ................................................................................. 1 1.2 太矿电牵引采煤机及其电控系统的发展历程 ..................................................... 4 1.3 电牵引采煤机及其控制系统的未来发展趋势 ..................................................... 8 1.4 本文主要研究内容 ............................................................................................... 10 2 采煤机分布式控制系统的架构设计与开发采煤机分布式控制系统的架构设计与开发 ......................................................... 12 2.1 采煤机分布式控制系统的总体架构 ................................................................... 13 2.2 采煤机分布式控制网络模型 ............................................................................... 15 2.3 采煤机分布式电控系统总体功能设计 ............................................................... 18 3 基于基于 CAN 总线的控制器的研发与检测总线的控制器的研发与检测 ............................................................... 24 3.1 可编程逻辑控制器 PLC 的应用经验 ................................................................. 24 3.2 主控制器的技术参数 ........................................................................................... 25 3.3 从控制器的技术参数 ........................................................................................... 27 3.4 控制器软件设计 ................................................................................................... 28 3.5 控制器的可靠性 ................................................................................................... 40 3.6 控制器的检测及检验 ........................................................................................... 41 4 分布式监控模块的开发分布式监控模块的开发 ......................................................................................... 45 4.1 分布式模块的研究 ............................................................................................... 46 4.2 分布式模块的可靠性测试 ................................................................................... 50 5 状态监测与故障诊断系统研究状态监测与故障诊断系统研究 ............................................................................. 56 5.1 采煤机故障及诊断技术存在的主要问题 ........................................................... 56 5.2 基于 CAN 总线的采煤机状态监测及故障诊断系统设计与研制 .................... 57 5.3 采煤机远程诊断系统设计 ................................................................................... 77 6 采煤机智能化功能设计与实现采煤机智能化功能设计与实现 ............................................................................. 80 6.1 滚筒高度自动调节技术 ....................................................................................... 80 6.2 牵引速度自动调节技术 ....................................................................................... 90 V 6.3 基于地理信息系统（GIS）的采煤机定位与煤层识别技术 ............................ 94 6.4 基于 TD-LTE 制式的采煤机无线数据传输系统 ............................................. 102 7 结论与展望结论与展望 ........................................................................................................... 109 7.1 结论 ..................................................................................................................... 109 7.2 展望 ..................................................................................................................... 110 参考文献参考文献 ................................................................................................................... 111 附录附录............................................................................................................................ 115 作者简历作者简历 ................................................................................................................... 119 学位论文原创性声明学位论文原创性声明 ............................................................................................... 121 学位论文数据集学位论文数据集 ....................................................................................................... 122 VI Contents Abstract ........................................................................................................................ II Contents ..................................................................................................................... VI List of Figures ......................................................................................................... VIII List of Tables ........................................................................................................... XIII 1 Introduction ............................................................................................................... 1 1.1 Development of the World Electric Haulage Shearer .............................................. 1 1.2 Development History of the Companys Electric Haulage Shearer and its Electronic Control System ............................................................................................................... 4 1.3 Future Development Trend of Electric Haulage Shearer and its Control System ... 8 1.4 The Main Work of this Article ............................................................................... 10 2 Research and Development of Distributed Control System for Shearer ........... 12 2.1 The Overall Architecture of the Distributed Control System of the Shearer ......... 13 2.2 Distributed Control Network Model for Coal Shearer .......................................... 15 2.3 The Overall Functional Design of Shearer Distributed Electronic Control System ...................................................................................................................................... 18 3 Development and Test of CAN Bus Controller .................................................... 24 3.1 Experience in PLC Application ............................................................................. 24 3.2 Technical Parameters of the Master Controller ...................................................... 25 3.3 Technical Parameters of the Secondary Controller ................................................ 27 3.4 Software Design of Controller ............................................................................... 28 3.5 The Reliability of the Controller is Defined .......................................................... 40 3.6 Controller Test and Inspection ............................................................................... 41 4 Development of Distributed Monitoring Module ................................................. 45 4.1 The Research of the Distributed Module ............................................................... 46 4.2 Reliability Testing of Distributed Modules ............................................................ 50 5 Research on Multi-sensor Ination Fusion Technology and Fault Diagnosis ...................................................................................................................................... 56 5.1 Main Problems of Shearer Fault and Diagnosis Technology ................................. 56 5.2 Design and Development of a Shearer Condition Monitoring and Fault Diagnosis System Based on CAN Bus ......................................................................................... 57 VII 5.3 Design of the Remote Diagnosis System of the Shearer ....................................... 77 6 Intelligent Design of Distributed Control System Based on Shearer ................. 80 6.1 Roller Height Automatic Adjustment Technology ................................................. 80 6.2 Automatic Haulage Speed Adjustment Technology ............................................... 90 6.3 Shearer Positioning and Coal Seam Identification Technology Based on Geographi