ZZ120000大采高支撑掩护式液压支架设计【含CAD图纸、说明书】
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翻译部分英语原文A Study on the Remote Monitoring System of Hydraulic Support Based on 3DVRYan Haifeng, Su Fengxiang,Cheng Zhihong ,Du ChanglongThe school of Mechanical and Electrical Engineering China University of Mining andTechnology XuZhou JiangSuAbstractThe framework of hydraulic support remote monitoring system for fully-mechanized coalface is investigated in this paper. The three-dimensional virtualreality technology (3DVR) is applied to the control of hydraulic support and the OPC (OLE for process control) communication technology) is used to obtain the important sensing data of hydraulic support,meanwhile, by using dynamics analysis and rapid solution based on intelligent algorithm, the virtual prototyping modeling of hydraulic support is driven. As a result, the hydraulic support working conditions reappeared synchronously and truly, the hydraulic support working process is remotely controlled.1. IntroductionHydraulic support is the main equipment of mechanized mining. Its function is not only to support the roof, maintain the space for safe operation, but also shift face conveyor and coal cutter. Therefore,monitoring the hydraulic working conditions andperformance to improve the support reliability is one of the key factors for the mechanized mining successfully.However, coal production environment of mechanized mining face is very bad and the force of the hydraulic support is unusually complicated. Currently, the site pressure monitoring is often used under a heavy working load and in a severe environment, but the quality of remote video monitoring image is much poor.General remote monitoring system uses plane interface so that site conditions cannot be fully reflected. Using the combination of virtual reality visualization with automatic remote monitoring can make control personnel to have a sense of immersive and thus they may judge accurately so that potential accidents will be eliminated and mine safety production and management will be promoted. This kind of technology can also be used to train miners who will be personally on the scene to experience and learn taking effective emergency measures to deal with dangerous situations in order to enhance the quality of personnel 1.2. System FrameworkThe system structure consists of four layers, from the bottom to top as follows: device layer, local control layer, network communication layer and HCI (humancomputer interaction) layer (Figure 1).2.1. Device LayerDevice layer, the final implementation part of the system, is at the bottom of the whole system. It is responsible for action implementation and data collection, mainly formed with hydraulic support, electro-hydraulic valve group and various types of sensors. Take two-leg shield support as an example, electro-hydraulic valve group includes 5 to 8 three position four-way electro-hydraulic valve to control legs, balanced jack, forepoling jack, spalling-rib protection jack, side protection jack, push slip jack and bottom lift jack. The sensors mainly collect the following data: legs pressures, balanced jack pressures, push conveyor jack displacement, balanced jack displacement etc.2.2. Local Control LayerLocal control layer, the key control layer of the system, controls the devices on the device layer and processes collected data mainly through deciding programs. The local PLC controller, made by the highperformance large-scale PLC (such as the S7-400) and 913 related modules, is placed along the tank. As the master (controllers located on every hydraulic support) viadata Profibus for the coordination among hydraulic supports, between the hydraulic support and coal cutter, the hydraulic supports and the scraper conveyor. Local explosion-proof industrial computer can implementb local monitoring and controlling of hydraulic supports along the underground tank. The support controller uses the embedded system or a small, efficient and reliable PLC (such as the S7-200) to integrate Profibus-DP interface and local control panel, to achieve the collection of various data and movement control of electro-hydraulic valve, thus to control the movement of hydraulic support. Figure 1. Framework of hydraulic supports remote monitoring system2.3. Network Communication LayerNetwork communication layer is responsible for the communication of upper and lower systems, including OPC Server, Simatic Net to achieve the communication between 3DVR and OPC Server, and Siemens WinCC to achieve the communication between common industrial configuration screen and OPC Server. Local PLC controller communicates with up-ground OPC server through 1000M Industrial Ethernet and fiber optics 2.2.4. Human-Computer Interaction LayerHuman-computer interaction layer is the top layer of the system, responsible for the display of all hydraulic supports state data, control of the command input and set of the system parameter. Hydraulic support 3DVR remote monitoring platform can run on a high performance PC. Virtual reality technology achieves human-computer interaction through the monitor and keyboard and mouse. It can also be output to the immersive virtual reality environment through highperformance graphics workstations, so that the user has left its sense of its territory. Condition parameters remote monitoring platform uses industrial control configuration software to configure general control configuration screen, easy for general users remote control operation. Historical data and alarm data go into SQL Server for archiving, easy to inquire and analyze.3. Achievement of hydraulic support 3DVR remote monitoring platformThe sensing test data which will be used in the process control of hydraulic support is inputted in longrange high-performance computers adopting OPC communications technology. By using dynamics analysis and rapid solution based on intelligent algorithm, the virtual prototyping model of hydraulic support is operated. Upper manual remote control commands are issued through the OPC at the scene of physical hydraulic support, thus three-dimensional virtual reality technology is used in hydraulic remote process control. As a result, the hydraulic support working conditions are synchronously truly reappeared and the hydraulic support working process is remotely controlled.3.1. Virtual reality scene modelingEstablishing the scene of virtual reality needs a large number of 3D models. Direct programming model isclearly unrealistic. 3D software (such as 3DS Max,Maya, etc.) could be adopted to establish model into virtual reality development platform and join the interactive effects. Hydraulic Support 3DVR (3DVirtual Reality) remote monitoring system mainly uses Virtools4.0 as the virtual reality development platform.Virtools4.0 is a 3D virtual reality software platformn developed by the French Dassault company on the basis of the latest PCS (Product-Context-Scenario) platform.Virtools can create high-quality visual effects and interactive content work through visual flowchart script interface and a powerful integrated rendering engine.Using SDK (Software Development Kit) and VSL (Virtools Scripting Language), you can create userdefined interactive scripts and applications through the corresponding API interface3.We use design department UG and SolidWorks design model with simple processing to import 3D max rendering given material and make the model more realistic, output to the Virtools as a virtual scene model,adopt graphical interactive programming in Virtools to achieve all hydraulic support actions (raise, drop, push conveyor, Surport shift, etc.), and use father-sonrelations between 2D Frame as well as module combinations to achieve control panel buttons and drop-down menu (Figure 2).Figure 2. Three-dimensional virtual scene andthe control panel3.2. Dynamics Analysis of Hydraulic supportDynamics analysis engine of hydraulic support is the core of the system. It uses multi-body dynamics,kinematics, hydraulics, surrounding rock control etc.theories to establish nonlinear system models,integrates a variety of transmission sense data from OPC Server, adopts advanced genetic algorithm as a solving strategy, calculates and analyzes with highperformance computing platform, provides information of current location of every component to virtual hydraulic support.The main part of two legs shield support is a parallel mechanism possessing two freedom degree, which can be established a equation group through the analysis,taking the legs length S1 and balanced-jacks length S2 as independent variables, angles of all components(front link, hinder link, leg, balanced-jack, goaf shield,and canopy) as unknown variables. So as long as the legs length and balanced-jacks length are monitored by the displacement sensor, we can solve the current work gesture of hydraulic support. But the equation group is a set of nonlinear equation, the genetic algorithm of efficient search is required. At the same time, the force status of the hydraulic support components can be obtained monitoring the pressure of leg and balanced jack through the pressure sensor.3.3. Communication between OPC Sever and the VirtoolsOPC (OLE for Process Control) is used for process control, taking OLE / COM system as the industrial communication standard of an application program,OPC provides a unified open interface for every dispersed sub-subsystem in the control area to solve the problems of sharing data among distributed subsystems of real-time monitoring system and unifying and coordinating control commands corresponding 4.Communication module between OPC Sever and Virtools is another key module of the system. We apply the Virtools SDK technology, use Visual C+. Net 2003 program, develop the Virtools OPC Sever communications module. The module gets the information needed for dynamics analysis module from OPC Sever, and then real time drives actions of virtual 3D hydraulic support in Virtools Dev, writes the control command that virtual control panel issued to OPC Sever in order to control the local physical hydraulic Support.4. ConclusionAlthough the application of VR in coal mine is still at the initial stage, with the improvement of the coal mining technology and mine safety increasingly, using the combination of visual virtual reality technology and industrial automation remote monitoring technology can promote mine safety production and management.It will be used more and more in coal production, and gradually infiltrated into all levels. The research in this area has broad prospects in the coal mine and other industries.References1 H.F.Yan,M.Gong ,D.F.Tang , “Development of the virtual reality system for hydralic supports on the full Mechanized mining face based on Virtools4.0” , Ming &Processing Equipment,LuoYang HeNan,2009,pp.14-162Siemens, “OPC - Open Connectivity ” , WinCC Online Help3 Dassault Systemes, 3DVIA Virtools 4.0 Online Reference4 OPC Foundation, “About OPC”,5 Z.J.Wang,Y.J.Wang,Y.M.Fu, “The system of mine 3D visual modeling and navigation based on visual reality technology”, Engineering of Surveying andMapping,HeiLongjiang,2006,pp.44-47中文翻译：基于3DVR的液压支架远程监控系统的研究摘要: 在本文中液压支架远程监控系统的框架是为了研究综采工作面。三维虚拟现实技术(3DVR)被应用到液压支架的控制和OPC(OLE程序控制)通信技术用来获取液压支架重要的遥感数据。同时,利用动力学分析和利用智能算法快速的解决了对液压支架虚拟的原型建模。这样液压支架的工作条件被同步的真实的再现，液压支架工作过程也被远程操控。1. 简介在机械化开采中液压支架是主要的设备。它的作用不仅是支撑顶板, 还为安全操作提供了一个空间,而且也能移动输送机和采煤机。因此，监测液压支架的工作条件和提高液压支架可靠性是成功的机械化开采最重要的关键因素之一。然而，机械化采煤工作面生产环境是非常差的。并且液压支架的受力通常是很复杂的。目前，压力监测点经常是在沉重的工作负荷和恶劣的环境下，而且远程视频监控图像质量是非常差的。一般的远程监控系统采用平面界面。所以，不能充分反映现场条件。虚拟现实可视化技术与自动远程监测的结合使用可以使操作人员有一种强烈的感官效果,因此他们能准确的判断并消除潜在的事故和提高矿山安全生产和管理。这种技术也可以用来训练矿工让他们身临其境来获得现场经验和学习采取有效的紧急措施来对付危险的情况这样来提高人员的能力1。2体系框架该系统的体系结构包括四层,从最底层到最高层如下:设备层、局部控制层、网络通讯层和HCI(人机交互)层(图1)。图1.液压支架远程监控系统的框架2.1设备层设备层, 是系统最后实施的部分、是整个系统的最底层。它是负责实施行动和数据收集、主要包括液压支架,电液阀组和各种类型的传感器。以两柱掩护式液压支架为例,电液阀组包括5至8个三位四通电液换向阀来控制立柱，平衡千斤顶，前梁千斤顶，护帮千斤顶，侧推千斤顶，推移千斤顶，抬底千斤顶。传感器主要收集下列数据：立柱压力,平衡千斤顶的压力,推移千斤顶位移、平衡千斤顶位移等。2.2局部控制层局部控制层，是系统最关键的控制层、主要是通过程序控制设备层的设备和所收集数据的过程。局部的PLC控制器,由高性能大规模可编程逻辑控制器PLC(如S7-400)和相关的模块组成,被放置在箱体里。作为主控控制器,它通过Profibus总线的数据与下一级的控制器交流（控制器是放在每个液压支架上）为了协调液压支架,液压支架和采煤机,液压支架和刮板输送机。局部防爆的工业计算机,能够很好地实现局部的监测和控制沿着地下水槽的液压支架。液压支架控制器采用嵌入式的系统或者一个很小的、高效的可靠的PLC(如s7 - 200系列)Profibus DP接口和局部控制面板相结合,来实现收集变量和控制电液阀的位移,从而来控制液压支架的运动。2.3网络通信层网络通信层主要负责上位机、下位机通信的系统,包括OPC Server、Simatic网络实现了3DVR与 OPC Server之间通信,西门子的WinCC实现了工业配置屏幕和OPC Server之间的沟通。局部的PLC控制器与 OPCserver通过1000兆工业以太网和纤维光学进行传达2。2.4人机交互层人机交互层是该系统最上的一层,负责显示所有液压支架的状态数据、输入命令的控制和一系列的系统参数。液压支架3DVR的远程监控平台可以在一个高性能的电脑上运行。虚拟现实技术可以通过监测、键盘、鼠标来实现人机交互。它也可以通过高性能图形工作站输出虚拟的现实环境,这样用户留下其对领域的感知。远程监控平台的条件参数是利用工业控制组态软件来配置一般控制的配置屏幕,对于一般用户很容易实现远程控制操作。历史的数据和重要的数据被送到SQL服务器,这样易于查询和分析。3液压支架3DVR远程监控平台的成就液压支架控制过程的传感测试数据被大量的输入到采用OPC通信技术的高性能计算机里。利用动力学分析和智能算法的快速解决方案,完成了液压支架的虚拟样机模型。上面手动远程控制命令通过OPC发送到现场的液压支架,从而三维的虚拟现实技术被用于液压支架远程过程控制。这样,液压支架工作条件被同步的真实再现并且液压支架工作过程被远程控制。3.1虚拟现实场景模型建立现场的虚拟现实需要大量的3D模型。直接的编程模型是显然不切实际的。可以使用3D软件(如3DS Max,Maya,等等。)，在虚拟现实开发平台中建立模型,并且参与交互作用。液压支架的3DVR（3D虚拟现实)远程监控系统主要使用Virtools4.0作为虚拟现实开发平台。Virtools4.0是一个3D虚拟实境软件平台由法国达索公司在最新的PCS(Product-Con
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