综采工作面液压支架测高传感器设计

高思伟; 谷敏永; 李殿鹏

doi:10.13272/j.issn.1671-251x.2024010089

综采工作面液压支架测高传感器设计

doi: 10.13272/j.issn.1671-251x.2024010089

北京天玛智控科技股份有限公司，北京　101399

基金项目: 国家重点研发计划资助项目（2023YFB3211005）。

详细信息

作者简介:
高思伟（1989—），男，四川绵阳人，助理研究员，硕士研究生，主要研究方向为自动化控制技术，E-mail：gaosw@tdmarco.com

中图分类号: TD355.4
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- 被引次数: 0
出版历程
- 收稿日期: 2024-01-25
- 修回日期: 2024-05-30
- 网络出版日期: 2024-06-24

Design of height measurement sensor for hydraulic support in fully mechanized working face

Beijing Tianma Intelligent Control Technology Co., Ltd., Beijing 101399, China

摘要

摘要: 针对综采工作面液压支架高度测量困难和可靠性、稳定性差等问题，设计了一种基于帕斯卡定律的液压支架测高传感器。该测高传感器内置一根细长液管，液管中充满甲基硅油，测高传感器两端安装压力传感器，通过测量密闭液管的两端压力，得到测高传感器两端位置的高度差。甲基硅油在环境温度变化时具有明显的热胀冷缩特性，会引起密闭空间内的压力急剧变化，影响测量精度，提出了一种补偿方法：采用波纹管存储一部分甲基硅油，利用波纹管自身的弹性补偿甲基硅油热胀冷缩造成的体积变化；并在软件中通过算法校准甲基硅油体积变化带来的密度变化，从而确保测高传感器的测量精度。试验结果表明：测高传感器可工作在0～40 ℃环境下，测量误差在4 cm以内。在薄煤层、中厚煤层综采工作面液压支架的现场应用结果表明：与人工测量结果相比，测高传感器的高度测量误差在5 cm以内，说明该传感器可靠性较高。
- 综采工作面 /
- 液压支架 /
- 测高传感器 /
- 压力传感器 /
- 波纹管 /
- 温度补偿 /
- 密度校准
Abstract: A hydraulic support height measueement sensor based on Pascal's law is designed to address the difficulties in measuring the height, reliability, and stability of hydraulic supports in fully mechanized working faces. The height measurement sensor is equipped with a slender liquid tube, which is filled with methyl silicone oil. Pressure sensors are installed at both ends of the height measuremenr sensor. By measuring the pressure at both ends of the sealed liquid tube, the height difference between the two ends of the height measuremenr sensor is obtained. Methyl silicone oil has obvious thermal expansion and contraction characteristics when the ambient temperature changes, which can cause a sharp change in pressure in a closed space and affect measurement precision. A compensation method is proposed. The method stores a portion of methyl silicone oil in a corrugated tube, and uses the elasticity of the corrugated tube itself to compensate for the volume change caused by thermal expansion and contraction of methyl silicone oil. The method calibrates the density change caused by the volume change of methyl silicone oil through algorithms in the software to ensure the measurement precision of the height measurement sensor. The test results show that the height measuremenr sensor can operate in an environment of 0-40 ℃, with a measurement error of less than 4 cm. The on-site application results of the hydraulic support in the fully mechanized working face of thin and medium thick coal seams show that compared with manual measurement results, the error of the height measurement sensor is within 5 cm, indicating high reliability of the sensor.
- fully mechanized working face /
- hydraulic support /
- height measurement sensor /
- pressure sensor /
- bellows /
- temperature compensation /
- density calibration

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图 1 测高传感器原理

Figure 1. Principle of height measurement sensor

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图 2 测高传感器硬件结构

Figure 2. Hardware structure of height measurement sensor

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图 3 I²C驱动提升电路

Figure 3. I²C drive lift circuit

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图 4 测高传感器外观结构

Figure 4. Appearance structure of height measurement sensor

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图 5 压力传感器及气密芯阀安装结构

Figure 5. Installation diagram of pressure sensor and airtight core valve

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图 6 测高传感器软件流程

Figure 6. Software flow of height measurement sensor

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表 1 甲基硅油密度与温度关系对应

Table 1. Correspondence between density and temperature of methyl silicone oil

理想测试温度/℃	密度/（g·cm⁻³）	实测温度/℃	密度平均值/（g·cm⁻³）
10	0.953 09	10.04	0.953 10
10	0.953 11	10.01	0.953 10
15	0.948 50	14.99	0.948 50
15	0.948 49	15.01	0.948 50
18	0.945 73	17.99	0.945 72
18	0.945 71	18.01	0.945 72
21	0.942 96	21.01	0.942 96
21	0.942 96	21.01	0.942 96
24	0.940 22	23.99	0.940 21
24	0.940 19	24.01	0.940 21
27	0.937 45	26.99	0.937 45
27	0.937 44	27.01	0.937 45
30	0.934 70	30.01	0.934 70
30	0.934 70	29.99	0.934 70
35	0.930 10	34.99	0.930 11
35	0.930 12	34.99	0.930 11
40	0.925 55	39.99	0.925 56
40	0.925 56	39.99	0.925 56

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表 2 高温到低温变化过程中的传感器数据

Table 2. Sensor data during high temperature to low temperature changes

温度/℃	高度/cm	下端压力/kPa	上端压力/kPa
40.08	154.16	140.24	126.26
35.00	153.04	130.32	116.36
30.02	152.81	123.43	109.41
25.04	153.61	115.09	100.95
20.05	153.21	108.73	94.56
15.03	152.93	103.68	89.46
9.98	153.85	99.74	85.37
5.01	152.67	95.84	81.51
0.04	153.20	92.48	78.03

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表 3 低温到高温变化过程中的传感器数据

Table 3. Sensor data during low temperature to high temperature changes

温度/℃	高度/cm	下端压力/kPa	上端压力/kPa
0.02	153.51	91.87	77.40
5.03	153.17	95.64	81.23
10.05	152.80	100.28	86.01
14.97	153.85	105.84	91.54
20.01	152.94	111.38	97.23
25.03	153.14	118.28	104.18
29.96	153.59	124.93	110.87
34.98	154.11	133.28	119.24
40.02	153.88	143.39	128.44

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表 4 常温下检测精度试验结果

Table 4. Test results of detection precision at normal temperature

实际高度/cm	检测高度/cm	环境温度/℃
0	0.773 220	24.484 61
100	98.620 932	24.484 61
200	201.481 950	24.093 79
300	302.477 290	24.289 20
400	399.922 510	24.289 20
500	500.598 310	24.386 90
600	598.760 030	24.386 90
700	701.423 10	24.386 90
800	800.505 50	24.483 90
900	898.608 90	24.483 90
1 000	999.288 90	24.483 90

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表 5 中厚煤层支架测高传感器数据对比

Table 5. Data comparison of support height sensor for medium-thick coal seam cm

支架号	初次安装		3个月后
支架号	检测值	人工测量值	检测值	人工测量值
20	376	373	369	372
29	348	343	365	367
39	366	363	359	357
49	363	360	364	368
60	348	348	363	361

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表 6 较薄煤层支架测高传感器数据对比

Table 6. Data comparison of support height sensor for thin coal seam cm

支架号	初次安装		3个月后
支架号	检测值	人工测量值	检测值	人工测量值
15	149	151	151	149
20	158	156	154	155
25	147	147	159	161
30	142	142	155	159
35	132	128	161	159

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