A generation method for the cutting height template of the shearer drum based on working condition triggering
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摘要: 针对采煤机在工作过程中易受不同工况条件的影响导致滚筒调高精度低的问题，提出了一种基于工况触发的采煤机滚筒截割高度模板生成方法。对采煤机历史传感器数据进行预处理和特征提取，选择影响滚筒高度调节的截割电动机电流、截割电动机温度、俯仰角、横滚角、牵引速度5维特征数据，构建用于生成滚筒截割高度模板的补偿回声状态网络（C−ESN）模型；建立工况触发机制，将采煤机传感器实时数据输入C−ESN模型，以测试误差为判断准则，识别当前采煤机的工况为正常区域、三角煤区域或异常工况；最后，C−ESN模型生成相应的滚筒截割高度模板。当三角煤区域和正常区域测试误差都大于阈值时，采用迁移学习方法对测试误差小的截割高度模板参数进行修正，以保证异常工况下截割高度模板的精度。基于现场采煤机实际数据的实验结果表明：左右滚筒截割高度模板与实际截割高度相比，在正常区域的最大误差分别为11.47，9.96 cm，在三角煤区域最大误差分别为12.91，7.94 cm，能够满足工程实际要求；与传统回声状态网络和径向基函数网络模型相比，C−ESN模型的精度在正常区域分别提升了54%和57%，在三角煤区域分别提升了10%和69%。Abstract: In order to solve the problem of low precision in drum height adjustment caused by different working conditions during the working process of the shearer, a generation method for cutting height template of the shearer drums based on working condition triggering is proposed. The method preprocesses and extracts features from historical sensor data of the shearer, selects 5-dimensional feature data that affect the adjustment of drum height, including cutting motor current, cutting motor temperature, pitch angle, roll angle, and traction speed. The method constructs a compensated echo state network (C-ESN) model for generating drum cutting height templates. The method establishes a working condition triggering mechanism, inputs real-time data from the shearer sensors into the C-ESN model. The method uses testing error as the judgment criterion to recognize the current working condition of the shearer as normal area, triangular coal area, or abnormal working condition. Finally, the C-ESN model generates the corresponding drum cutting height template. When the testing errors in both the triangular coal area and the normal area are greater than the threshold, transfer learning method is used to correct the parameters of the cutting height template with small testing errors to ensure the precision of the cutting height template under abnormal working conditions. The experimental results based on actual data of on-site coal mining machines show that compared with the actual cutting height, the maximum errors of the left and right drum cutting height templates in the normal area are 11.47 cm and 9.96 cm, respectively, and in the triangular coal area are 12.91 cm and 7.94 cm, respectively.The results can meet the practical requirements of engineering. Compared with traditional echo state network and radial basis function network models, the precision of the C-ESN model has been improved by 54% and 57% in the normal region, and by 10% and 69% in the triangular coal region, respectively.
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图 3 采煤机滚筒截割高度模板生成过程
Figure 3. Generating process for cutting height template of shearer drum
表 1 工况划分
Table 1. Classification of working condition
工况 截割工艺 正常区域 从机头向机尾正常割煤 三角煤区域 清浮煤 清浮煤返回 斜切进刀 斜切进刀返回 
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表 2 807工作面部分采煤机特征数据
Table 2. Part of the characteristic data of shearer in 807 working face
时间 温度/℃ 电流/A 俯仰角/（°） 横滚角/（°） 牵引速度/（m·min−1） 2023-03-27 T03:03 75.26 84.27 −0.06 −0.49 7.14 2023-03-29 T02:06 70.17 68.23 1.28 −0.16 6.15 2023-03-29 T03:46 76.25 43.75 0.61 −0.21 8.16 2023-03-30 T01:37 71.96 80.80 2.98 −0.35 7.96
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表 3 部分截割高度模板数值
Table 3. Partial values of cutting height template
p h1/cm h2/cm 8 265.0 175.1 28 257.9 182.7 48 233.8 179.4 68 242.8 182.7 88 240.9 179.0 108 237.6 188.6 128 241.7 182.8 146 188.9 194.9
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表 4 不同模型正常区域滚筒高度误差对比
Table 4. Comparison of drum height errors in normal areas of different models
模型 滚筒 NRMSE MAE 最大偏差/cm RBF 左滚筒 0.566 0.039 15.356 右滚筒 0.444 0.035 25.442 ESN 左滚筒 0.383 0.025 12.815 右滚筒 0.376 0.037 22.707 C−ESN 左滚筒 0.338 0.023 9.956 右滚筒 0.164 0.016 11.471
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表 5 不同模型三角煤区域滚筒高度误差对比
Table 5. Comparison of drum height errors in triangular coal regions of different models
模型 滚筒 NRMSE MAE 最大偏差/cm RBF 左滚筒 0.434 0.025 24.078 右滚筒 0.267 0.010 36.704 ESN 左滚筒 0.372 0.040 24.368 右滚筒 0.221 0.029 15.366 C−ESN 左滚筒 0.140 0.018 12.910 右滚筒 0.073 0.009 7.940
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