基于PPDCAN的综放支架液压油缸故障诊断方法

Fault diagnosis method for hydraulic cylinders of fully mechanized top-coal caving supports based on an PPDCAN

  • 摘要: 针对综放支架液压油缸泄漏故障隐蔽性强、双通道压力耦合复杂、不同油缸样本长度差异显著以及传统数据驱动方法物理可解释性不足等问题,提出一种基于物理先验与双重交叉注意力网络的综放支架液压油缸故障诊断方法。依托的液压油缸泄漏故障模拟实验系统,采集6种规格油缸在正常、内部泄漏、无杆腔外部泄漏、有杆腔外部泄漏及复合泄漏5种工况下的双通道压力信号数据。针对原始信号样本长度不一致、长序列建模开销大以及不同油缸之间存在明显分布偏移等问题,采用Z-Score标准化、分段切分、线性插值以及短时傅里叶变换构建统一的二维时频表示。在此基础上,设计物理先验双重交叉注意力网络,利用双重交叉注意力模块建立双通道压力信号的对称交互关系,并结合Transformer编码器实现深层时频特征提取;同时引入由分类损失与物理先验引导的泄漏一致性损失组成的复合目标函数,使模型在学习故障判别信息的同时兼顾液压泄漏机理约束。实验结果表明:所提方法在测试集上的准确率达到91.76%,外泄故障融合准确率达到96.73%,相较于对比模型中的最优结果分别提高3.27%和3.73%;消融实验进一步验证了双重交叉注意力模块与物理先验损失的有效性 。该方法能够在稀疏流体场压力信息条件下实现对综放支架液压油缸泄漏故障的有效识别,具有良好的工程应用潜力。

     

    Abstract: To address the challenges of strong concealment, complex dual-channel pressure coupling, significant differences in sample lengths across various hydraulic cylinders, and the lack of physical interpretability in traditional data-driven methods, a fault diagnosis method for hydraulic cylinder leakage in fully mechanized top-coal caving supports is proposed, based on physics priors and dual cross-attention networks. The method utilizes a hydraulic cylinder leakage fault simulation experimental system, which collects dual-channel pressure signals from cylinders of six different specifications under five working conditions: normal, internal leakage, external leakage in the rodless chamber, external leakage in the rod chamber, and composite leakage. To address issues such as inconsistent sample lengths, high computational costs of long-sequence modeling, and significant distribution shifts between different cylinders, a unified two-dimensional time-frequency representation is constructed using Z-score normalization, segmentation, linear interpolation, and Short-Time Fourier Transform. A physics-informed dual cross-attention network is then designed, with the dual cross-attention module establishing a symmetric interaction relationship between the dual-channel pressure signals, while a Transformer encoder is employed for deep time-frequency feature extraction. Additionally, a composite objective function is introduced, consisting of a classification loss and a physics-prior-guided leakage consistency loss, allowing the model to learn fault discrimination information while adhering to hydraulic leakage mechanisms. Experimental results show that the proposed method achieves an accuracy of 91.76% on the test set, with a fusion accuracy of 96.73% for external leakage faults, representing improvements of 3.27% and 3.73%, respectively, compared to the best baseline models. Ablation studies further confirm the effectiveness of the dual cross-attention module and the physics-prior loss. This method effectively identifies leakage faults in hydraulic cylinders of fully mechanized top-coal caving supports under sparse fluid field pressure information conditions, demonstrating strong potential for practical engineering applications.

     

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