基于16位单片机的液压支架控制器开发.pdf

万方数据 万方数据 摘要 I 基于基于 16 位单片机的液压支架控制器开发位单片机的液压支架控制器开发 摘摘 要要 本课题是国家国际科技合作专项（S2013ZR0493） “无人值守工作面液 压支架电液控制系统的研制”的主要内容。立项以来，已开发出基于 C8051F020 单片机的 ZDYZ-JK 型液压支架间架控制器，并于 2013 年 7 月 起，在晋煤集团古书院矿进行了工业性试验，在工业性试验过程中，还存 在着系统功能缺少，产品性能稳定性不足等问题。随着技术的进一步发展， 国内电液控制技术水平不断进步，功能不断完善，且煤矿自动化生产对液 压支架的自动控制要求不断提高。 针对上述问题，项目组开展了基于 16 位单片机的电液控制系统研制， 确定了液压支架控制器的总体设计方案，开发了部分软硬件。但与国内外 先进的系统相比，结合本项目上一代控制器在井下运行的实际情况，现有 设计方案仍存在一定的缺陷。因此，本课题的研究内容就是在现有第二代 支架控制器设计方案的基础上，改进各项设计，完善有关功能。并根据项 目实际需求，开展液压支架乳化液高压反冲洗过滤站控制器的研究，制定 其总体设计方案，开发其硬件软件。本文主要研究内容如下 1、通过借鉴国内外先进的支架控制器，总结已开发成功的支架控制器 井下运行经验，分析现有方案的缺陷，提出了基于 16 位单片机的支架控制 器改进设计方案，进行了硬件电路设计、开发了系统应用程序、完善了系 统功能。 2、 依据改进设计方案，在硬件电路方面重新设计了电磁阀驱动电路， 提高了控制器驱动的可靠性；提出了电源电路、通信电路的 EMC 措施，提 高了控制器抗扰性。在系统应用软件方面开发了液压支架姿态调整程序、 液压支架双向排序程序、液压支架控制警示程序、液压支架反冲洗过滤程 序、液压支架故障诊断程序等程序；改进了模拟量采集程序、急停程序等， 拓展了液压支架控制器的功能，提高了控制器的实用性。在实验室试验平 台上反复对改进型液压支架控制器进行试验，验证了设计方案，检验了各 项程序运行的稳定性和可靠性。 3、研究了液压支架乳化液高压反冲洗过滤站控制技术，提出了控制器 万方数据 太原理工大学硕士研究生学位论文 II 的总体方案。通过分析乳化液高压反冲洗过滤站的控制需求，确定其过滤 站控制器的硬件架构，制定控制器控制模式及各项功能。 4、开发了液压支架乳化液高压反冲洗过滤站控制器，提出了控制器运 行的三种操作模式自动控制、半自动控制、手动控制。开发了过滤站控 制器硬件电路，设计了三种操作模式的控制程序以及传感器故障、滤网故 障等故障诊断程序及参数设置程序。通过进行实验室调试，检验了各项功 能的运行情况，实现了乳化液高压反冲洗过滤站的自动冲洗作业，提高了 系统的自动化程度和系统可靠性。 关键词关键词液压支架，电液控制系统，支架控制器，乳化液，高压反冲洗。 万方数据 ABSTRACT III Development of the Hydraulic Supports Controller Based on 16-bit Microcomputer ABSTRACT This subject is the main content of national and international scientific and technological cooperation project 0S2013ZR0493 ,named“ Development of electro hydraulic control system for hydraulic support on working face“. The project has been developed ZDYZ-JK type hydraulic support controller based on C8051F020 mcu. The industrial test in Gushuyuan Coal Mine of JAMG has been carried out from July 2013.In the process of industrial test, there are still a lack of system function and a poor product perance and stability. With the further development of technology, the domestic electric hydraulic control technology level has been continuously improved, the function has been improved, and the automatic control requirement of the hydraulic support of the coal mine automation production is continuously improved. In view of the above problems,, the project team has developed electric hydraulic control system based on 16 single chip microcomputer, the overall design scheme of the hydraulic support controller has been determined, and the hardware and software of the system has been developed. Compared with the domestic and foreign advanced systems, combined with the actual underground working situation of the last generation controller ,the existing design program still has some defects. So the research content of this paper is to advance the design and perfect the relevant functions based on the design of the existing second generation controller. In addition, the research content of this paper is to carry out the research of the hydraulic support emulsion high pressure anti filter station controller including develop its overall design program and its hardware and software ,which meeting the the actual needs of the project.The main research contents of this paper are as follows 1.Referring to the domestic and foreign advanced bracket system, 万方数据 太原理工大学硕士研究生学位论文 IV combining underground operation experience in the first generation of controller, the improved design scheme is design by summarizing and analyzing the hardware circuit design, software process design and function setting of existing second generation stent controller design scheme. 2.The drive circuit of the solenoid valve has been designed to improve the reliability of the controller. The EMC design of the power circuit and the communication circuit has been carried out to improve the anti-interference perance of the controller. The hydraulic support posture adjustment procedures, hydraulic support two-way sorting procedures, hydraulic support control warning procedures, hydraulic support anti filter, hydraulic support fault diagnosis procedures has been edited to expand the function of the hydraulic support controller and enhance the practicality of the controller. The test of improved hydraulic support controller has been put into practice to verify the design scheme and test the stability of the program in the test plat. 3. The overall plan of emulsion high pressure back ing filtering station controller has been drew up. Through analyzing the control demand of high pressure filter, the hardware structure of the controller of the filter station is determined, and the control mode and the function of the controller are established. 4. The hydraulic support emulsion high-pressure backwash filter station controller has been developed, and the three modes of controller operation automatic control, semi-automatic control and manual control has been put forward, including controller hardware circuit, the control program of three modes, the program of sensor fault, filter fault diagnosis and the parameters setting procedures. Through the laboratory test, the operation of the various functions has been examined. The research of controller has achieved automation of the emulsion high pressure back ing filter station is realized, which improves the systems automation degree and system reliability. KEY WORDS Hydraulic support; Electro-hydraulic control system; Support controller; Emulsion; High pressure back ing 万方数据 目 录 V 目目 录录 第一章第一章 绪绪 论论 .......................................................................................................................... 1 1.1 课题研究的背景及意义 .................................................................................................. 1 1.1.1 无人值守综采工作面 ............................................................................................... 1 1.1.2 液压支架电液控制技术 ........................................................................................... 3 1.1.3 液压支架乳化液反冲洗过滤站 ............................................................................... 4 1.2 液压支架电液控制器国内外发展与现状 ...................................................................... 5 1.3 液压支架乳化液反冲洗过滤站控制器国内外发展与现状 .......................................... 5 1.3.1 国内发展与现状 ....................................................................................................... 5 1.3.2 国外发展与现状 ....................................................................................................... 6 1.4 本课题研究现状及问题 .................................................................................................. 6 1.5 本课题研究目标及主要内容 .......................................................................................... 7 第二章第二章 液压支架电液控制系统支架控制器改进设计方案液压支架电液控制系统支架控制器改进设计方案 .................................................. 9 2.1 液压支架控制器 .............................................................................................................. 9 2.2 现有液压支架电液控制器设计及分析 ........................................................................ 10 2.2.1 现有设计 ................................................................................................................. 10 2.2.2 现有设计分析 ......................................................................................................... 11 2.3 液压支架电液控制系统支架控制器改进设计方案 .................................................... 12 2.3.1 功能改进 ................................................................................................................. 12 2.3.2 硬件电路改进 ......................................................................................................... 15 2.3.3 软件改进 ................................................................................................................. 16 2.4 本章小结 ........................................................................................................................ 18 第三章第三章 液压支架电液控制系统支架控液压支架电液控制系统支架控制器改进开发制器改进开发 ........................................................ 19 3.1 支架控制器硬件设计 .................................................................................................... 19 3.1.1 电磁先导阀驱动电路 ............................................................................................. 19 3.1.2 通信电路 ................................................................................................................. 22 3.1.3 电源电路设计 ......................................................................................................... 23 3.2 支架控制器软件设计 .................................................................................................... 24 3.2.1 液压支架姿态调整程序 ......................................................................................... 25 3.2.2 液压支架双向排序程序 ......................................................................................... 26 3.2.3 液压支架反冲洗过滤程序 ..................................................................................... 28 3.2.4 液压支架控制警示程序 ......................................................................................... 29 3.2.5 传感器故障诊断程序 ............................................................................................. 30 万方数据 太原理工大学硕士研究生学位论文 VI 3.2.6 模拟量采集程序 ..................................................................................................... 30 3.2.6 急停程序 ................................................................................................................. 32 3.3 实验室试验 ................................................................................................................... 32 3.3.1 实验室试验平台 ..................................................................................................... 33 3.3.2 改进型液压支架控制器功能试验 ......................................................................... 33 3.3.3 改进型液压支架控制器驱动电路试验 ................................................................. 36 3.4 本章小结 ....................................................................................................................... 37 第四章第四章 液压支架乳化液高压反冲洗过滤站控制器总体设计方案液压支架乳化液高压反冲洗过滤站控制器总体设计方案 ................................... 39 4.1 液压支架乳化液高压反冲洗过滤站 ........................................................................... 39 4.1.1 简介 ......................................................................................................................... 39 4.1.2 过滤站控制需求分析 ............................................................................................. 42 4.2 控制器整体方案设计 ................................................................................................... 43 4.3 控制器功能 ................................................................................................................... 44 4.3.1 控制模式 ................................................................................................................. 44 4.3.2 过滤站监测功能 ..................................................................................................... 45 4.3.3 故障诊断功能 ......................................................................................................... 45 4.3.4 参数设置 ................................................................................................................. 47 4.3.5 急停功能 ................................................................................................................. 47 4.4 控制器的主要技术指标 ............................................................................................... 47 4.5 本章小结 ....................................................................................................................... 48 第五章第五章 液压支架乳化液高压反冲洗过滤站控制器开发液压支架乳化液高压反冲洗过滤站控制器开发 ................................................... 49 5.1 控制器硬件设计 ........................................................................................................... 49 5.2 控制器软件设计 ........................................................................................................... 49 5.2.1 主程序 ..................................................................................................................... 49 5.2.2 手动控制程序 ......................................................................................................... 50 5.2.3 半自动控制程序 ..................................................................................................... 51 5.2.4 自动控制程序 ......................................................................................................... 52 5.2.5 故障诊断程序 ......................................................................................................... 53 5.3 控制器实验室调试 ....................................................................................................... 54 5.3.1 试验平台 ................................................................................................................. 54 5.3.2 功能调试 ................................................................................................................. 55 5.4 本章小结 ....................................................................................................................... 57 第六章第六章 可靠性措施及稳定性测试可靠性措施及稳定性测试 ....................................................................................... 59 6.1 控制器硬软件可靠性措施 ........................................................................................... 59 万方数据 目 录 VII 6.1.1 控制器硬件可靠性措施 ......................................................................................... 59 6.1.2 控制器软件可靠性措施 ......................................................................................... 60 6.2 控制器稳定性测试 ........................................................................................................ 61 6.2.1 支架控制器工作环境温度试验 ............................................................................. 61 6.2.2 控制器功耗试验 ..................................................................................................... 63 6.2.3 电磁兼容性试验 ..................................................................................................... 64 6.3 本章小结 ........................................................................................................................ 67 第七章第七章 结论与展望结论与展望 ................................................................................................................ 69 7.1 结论 ................................................................................................................................ 69 7.2 展望 ................................................................................................................................ 70 参考文献参考文献 .................................................................................................................................. 73 致致 谢谢 ........................................................................................................................................ 77 作者在攻读硕士学位期间的研究成果作者在攻读硕士学位期间的研究成果 .................................................................................. 79 发表的科技论文 .............