Automatic height adjustment technology of shearer based on cutting roof and floor height prediction model
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摘要: 传统的煤层截割路径规划通过几何控制、规划计算等方式对采煤机滚筒高度进行预测，但存在预测的数据误差较大、无法适应地质条件变化的问题。针对上述问题，提出了一种基于截割顶底板高度预测模型的采煤机自动调高技术。首先，分析了影响截割顶底板高度的因素，指出影响顶底板高度的主要因素包括煤层的起伏变化数据、历史截割数据、刮板输送机的高程数据及人工操作记录，将上述4类数据融合处理，建立以长短期记忆（LSTM）模型和灰色马尔可夫模型为基础的截割顶底板高度预测模型，通过算法模型预测出截割顶底板的高度。然后，以截割顶底板的高度数据为基础，结合采煤机位姿和空间坐标，建立计算滚筒高度的几何模型，同时依据刮板输送机上窜下滑量及是否执行加减刀工艺等因素进行修正，最终将顶底板高度序列转换为滚筒高度序列，即将截割顶底板高度转换为采煤机滚筒的目标高度，由采煤机执行到目标高度，实现滚筒自动调高工业性试验结果表明：① 在自动调高技术的控制下，顶滚筒和底滚筒的预测高度与实际高度偏差值有90%的数据量均在10 cm以内，滚筒的预测高度和实际高度具有明显的一致性。② 与传统手动控制方式相比，中部截割一刀煤的人工干预调高次数由49次下降为21次，说明截割顶底板的高度预测模型和计算滚筒高度的几何模型是准确合理的，采煤机滚筒的自动调高技术是可行的。Abstract: The traditional coal seam cutting path planning predicts the height of the drum through geometric control, planning calculation, and other methods. But there are problems with large data errors in planning and prediction and inability to adapt to changes in geological conditions. In order to solve the above problems, a shearer automatic height adjustment technology based on a cutting roof and floor height prediction model is proposed. Firstly, the factors affecting the height of the cutting roof and floor are analyzed. It is pointed out that the main factors affecting the height of the cutting roof and floor include the fluctuation data of the coal seam, historical cutting data, elevation data of the scraper conveyor, and manual operation records. The above four types of data are fused and processed to establish a cutting roof and floor height prediction algorithm model based on long short term memory (LSTM) model and gray Markov model. The height of the cutting roof and floor is predicted through an algorithmic model. Secondly, based on the height data of the cutting roof and floor, combined with the position and posture and spatial coordinates of the shearer, a geometric model for calculating the height of the drum is established. At the same time, correction is made according to factors such as the sliding amount of the scraper conveyor and whether the addition and subtraction process is carried out. Finally, the height sequence of the roof and floor is converted into a drum height sequence. The cutting roof and floor height is converted into the target height of the shearer drum, which is executed by the shearer to the target height, achieving automatic adjustment of the drum height. The industrial test results show the following points. ① Under the control of automatic height adjustment technology, 90% of the predicted height deviation values of the roof and floor drums are within 10 cm of the actual height. The predicted height of the drums is significantly consistent with the actual height. ② Compared with traditional manual control methods, the number of manual intervention height adjustment times for cutting coal in the middle has decreased from 49 to 21. It indicates that the height prediction model for cutting the roof and floor and the geometric model for calculating the height of the drum are accurate and reasonable, and the automatic height adjustment technology for the shearer drum is feasible.
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图 2 截割顶底板高度预测算法流程
Figure 2. Algorithm process for predicting the height of the cutting roof and floor
图 9 上位机控制软件和采煤机控制系统关系
Figure 9. Relationship between upper computer control software and shear control system
图 10 采煤机滚筒的实际高度与预测高度对比结果
Figure 10. Comparison between the actual height and predicted of the shearer drum
图 11 自动调高方式下司机的干预次数与传统手动调高方式下司机的干预次数对比
Figure 11. Comparison of the intervention frequency of drivers under automatic height adjustment mode and traditional manual height adjustment mode
表 1 试验工作面地质情况
Table 1. Geological conditions of the coal mining face
煤层厚度/m 煤层倾角/（°） 基本顶厚度/m 直接顶厚度/m 底板厚度/m 1.7～3.0 1～5 9.8 6.6 8.0 
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表 2 预测高度和实际高度偏差情况
Table 2. Deviation between predicted height and actual height
位置 偏差/cm 占比/% 顶板 ≤5 76.69 ≤10 94.66 ≤15 100 底板 ≤5 91.74 ≤10 97.69 ≤15 100
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