电牵引采煤机控制系统测试平台关键技术研究.pdf

工程硕士专业学位论文 电牵引采煤机控制系统测试平台 关键技术研究 Research on Key Technologies of Test Plat for Electric Haulage Shearer Control System 作 者周红亚 导 师谭 超 副教授 中国矿业大学 二〇二一年五月 万方数据 学位论文使用授权声明学位论文使用授权声明 本人完全了解中国矿业大学有关保留、使用学位论文的规定，同意本人所撰 写的学位论文的使用授权按照学校的管理规定处理 作为申请学位的条件之一， 学位论文著作权拥有者须授权所在学校拥有学位 论文的部分使用权，即①学校档案馆和图书馆有权保留学位论文的纸质版和电 子版，可以使用影印、缩印或扫描等复制手段保存和汇编学位论文；②为教学和 科研目的，学校档案馆和图书馆可以将公开的学位论文作为资料在档案馆、图书 馆等场所或在校园网上供校内师生阅读、浏览。另外，根据有关法规，同意中国 国家图书馆保存研究生学位论文。 （保密的学位论文在解密后适用本授权书） 。 作者签名 导师签名 年 月 日 年 月 日 万方数据 中图分类号 TD421 学校代码 10290 UDC 622 密 级 公开 中国矿业大学 工程硕士专业学位论文 电牵引采煤机控制系统测试平台关键技术研究 Research on Key Technologies of Test Plat for Electric Haulage Shearer Control System 作 者 周红亚 导 师 谭超 副教授 申请学位 工程硕士专业学位 培养单位 机电工程学院 学科专业 机械工程 研究方向 煤矿机电装备自动化 答辩委员会主席 杨寅威副教授 评 阅 人 二○二一年五月 万方数据 致谢致谢 光阴似箭，岁月如梭，回首矿大三年求学时光，感慨万千。非常幸运能够在 中国矿业大学这座百年学府中度过我宝贵的三年时光， 非常幸运遇到了认真的老 师，可爱的同学。我会永远心怀感激，会为我是矿大学子而感到骄傲。 首先感谢我的导师谭超副教授， 本文是在导师的悉心指导下完成的。 三年来， 导师在我的学业上谆谆教诲，在生活上给予关怀和爱护。他敏锐的思维、严谨的 治学态度、渊博的学识、诚挚谦虚的品格和宽厚善良的处世方式，永远值得我学 习。 遇到谭超老师， 成为他的学生， 是我的幸运， 我只有更努力才能够不负师恩。 在此，向恩师谭超老师表达我最崇高的敬意和衷心的感谢。 感谢课题组王忠宾、司垒、刘新华、杨寅威、闫海峰、戴剑博和邹筱瑜等老 师在课题研究和科研实践中给予的热忱鼓励和悉心指导。 还要感谢校外导师厉军 老师对我在学业上的帮助。他们运筹帷幄、睿智深邃，是我学习的榜样和追逐的 目标在这里同样对他们致以深深的敬意 另外感谢课题组路绪良、魏东、刘博文、李小玉、葛逸鹏、吴越、吴虹霖、 刘朋、安晓飞、李祖旭、简圣鸿、张哲豪等同门师兄师弟在论文撰写期间提供的 大力支持和无私帮助，在此致以最真挚的谢意。 感谢我的同伴田丰、张磊、张习，当我在生活和学习上遇到困难时，全力帮 助我度过难关。在彼此的鼓励中，我们在成为越来越好的人。 感谢父母的养育之恩，在我求学期间给予我始终如一的鼓励、关怀和帮助。 感谢我的母校，感谢这座历久弥新的百年学府，让我在三年美好时光里充实 了自己，让我有足够勇气到社会拼搏。 最后，感谢各位专家和学者在百忙之中审阅我的论文，并给予宝贵的指导， 在此谨向各位专家学者表示衷心的感谢 万方数据 I 摘摘 要要 采煤机作为综采成套装备的重要组成部分， 是实现煤矿安全高效生产的关键 设备之一，其自动化水平是制约综采工作面“无人化”或“少人化”发展的首要 因素。控制器作为采煤机的核心部件，在下井进入正式运行之前，进行全面的性 能和功能测试，对保证采煤机可靠性至关重要。本文研究 MG900/2210-WD 型采 煤机控制系统的测试技术。 为了测试采煤机控制系统的操作控制及故障诊断功能， 研究了基于数字总线 驱动的采煤机控制系统测试方法，设计了基于 CANopen 控制网络的主从通讯模 块，开发了采煤机真实工况与故障模拟系统，论文主要研究内容如下 （1）分析了采煤机的基本结构和工作机理，研究了采煤机控制系统组成和 主控回路中关键部件，设计了采煤机控制系统的数字总线网络、关键部件控制分 站及其测试驱动方案，构建了采煤机控制系统测试平台。 （2）分析了 CANopen 的基本原理、通信对象和对象字典，建立了基于 CanFestival 协议栈的采煤机控制系统主从通讯模型，设计了基于 CiA 301 通信子 协议和设备子协议的心跳模拟器、 主从分站对象字典、 PDO 配置表、分站地址分 配表和 COB-ID 通讯标识符分配表， 给出了采煤机控制系统与测试平台的连接方 案。 （3）建立了采煤机的机械结构、电气传动部件、电机、传感器和操作面板 的参数化配置文件，设计了采煤机遥控器操作站仿真模块，实现了模拟发送操作 指令驱动采煤机控制器的功能。给出了典型工况下采煤机速度线性拟合、温度变 化拟合和摇臂上升拟合等驱动模块，开发了基于 UML 的测试平台驱动软件。 （4）设计了采煤机监控系统的网页交互界面和基于 Unity 3D 的采煤机三维 模型，开发了故障数据模拟软件,在西安煤矿机械有限公司开展了采煤机控制系 统测试实验，测试了 MG900/2210-WD 型电牵引采煤机控制器的控制及保护功 能，对测试平台进行了实验验证，为采煤机控制系统进一步的功能完善和性能提 升奠定了良好基础。 该论文有图 52 幅，表 26 个，参考文献 91 篇。 关键词关键词采煤机；采煤机控制系统；CANopen；工况模拟系统；数字驱动技术 万方数据 II Abstract As an important part of the complete set of fully mechanized mining equipment, shearer is one of the key equipment to achieve safe and efficient production in coal mine. Its automation level is the primary factor restricting the development of “unmanned“ or “less humanized“ in fully mechanized face. As the core component of the shearer, the controller has a comprehensive perance and function test before entering the al operation, which is very important to ensure the reliability of the shearer. This paper studies the test technology of MG900/2210-WD shearer control system. In order to test the operation control and fault diagnosis function of shearer control system, the test of shearer control system based on digital bus driver is studied. The master-slave communication module based on CANopen control network is designed. The real working condition and fault simulation system of shearer is developed. The main contents of this paper are as follows 1 The basic structure and working mechanism of the shearer are analyzed. The composition of the shearer control system and the key components in the main control loop are studied. The digital bus network of shearer control system, the control substation of key components and its test driving scheme are designed. The test plat of shearer control system is constructed. 2 The basic principle of CANopen, communication object and object dictionary are analyzed. The master-slave communication model of shearer control system based on CanFestival protocol stack is established. The heartbeat simulator, master-slave substation object dictionary, PDO configuration table, substation address allocation table and COB-ID communication identifier allocation table based on CiA 301 communication sub protocol and device sub protocol are designed. The connection scheme between the shearer control system and the test plat is given. 3 The parametric configuration files of mechanical structure, electric drive components, motor sensor and operation panel of shearer are established. The simulation module of shearer remote control operation station is designed, and the function of driving shearer controller by simulating sending operation instructions is realized. The driving modules of speed linear fitting, temperature change fitting and rocker arm rising fitting under typical working conditions are given. The driving software of test plat based on UML is developed. 万方数据 III 4 The interactive interface of web page and three-dimensional model of shearer based on Unity 3D are designed. The fault data simulation software is developed. The test experiment of shearer control system is carried out in Xian Coal Mine Machinery Co., Ltd. The control and protection functions of MG900/2210-WD electric haulage shearer controller are tested. The test plat is verified by experiments, which lays a good foundation for further function improvement and perance improvement of shearer control system. There are 52 figures, 26tables and 91 references in the thesis. Keywords shearer; shearer control system; CANopen; working condition simulation system; digital drive technology 万方数据 IV 目目 录录 摘摘 要要............................................................................................................................ 1 目目 录录......................................................................................................................... IV 图清单图清单...................................................................................................................... VIII 表清单表清单......................................................................................................................... XI 变量注释表变量注释表 ............................................................................................................. XIII 1 绪论绪论............................................................................................................................ 1 1.1 课题来源及背景 ..................................................................................................... 1 1.2 课题研究现状及存在的问题 ................................................................................. 2 1.3 课题研究内容与方法 ............................................................................................. 7 1.4 课题研究意义 ......................................................................................................... 7 1.5 论文结构 ................................................................................................................. 8 2 采煤机控制系统测试平台总体设计采煤机控制系统测试平台总体设计 ....................................................................... 9 2.1 采煤机的基本结构与工作机理 ............................................................................. 9 2.2 采煤机总线型控制系统设计 ............................................................................... 11 2.3 采煤机控制系统总线架构 ................................................................................... 16 2.4 采煤机控制系统测试平台的总体方案设计 ....................................................... 18 2.5 本章小结 ............................................................................................................... 19 3 采煤机控制系统测试平台的总线模拟驱动协议设计采煤机控制系统测试平台的总线模拟驱动协议设计 ......................................... 20 3.1 CAN 总线 .............................................................................................................. 20 3.2 CANopen 协议 ...................................................................................................... 21 3.3 基于 CanFestival 协议栈的主从通讯技术研究 ................................................. 23 3.4 主从站对象字典建立 ........................................................................................... 26 3.5 采煤机控制系统 4 路 CAN 总线结构 ................................................................ 32 3.6 本章小节 ............................................................................................................... 33 4 采煤机真实工况模拟驱动测试技术研究采煤机真实工况模拟驱动测试技术研究 ............................................................. 34 4.1 采煤机真实工况模拟发生系统总体设计 ........................................................... 34 4.2 模拟工况生成 ....................................................................................................... 39 4.3 采煤机测试平台驱动系统建模 ........................................................................... 46 4.4 本章小结 ............................................................................................................... 56 5 采煤机控制系统测试实验采煤机控制系统测试实验 ..................................................................................... 57 万方数据 V 5.1 测试平台软件设计...............................................................................................57 5.2 实验平台设计.......................................................................................................60 5.3 实验验证...............................................................................................................61 5.4 本章小结...............................................................................................................68 6 总结与展望总结与展望 .............................................................................................................69 6.1 总结.......................................................................................................................69 6.2 展望.......................................................................................................................69 参考文献参考文献 .....................................................................................................................71 作者简历作者简历 .....................................................................................................................77 学位论文原创性声明学位论文原创性声明 .................................................................................................78 学位论文数据集学位论文数据集 .........................................................................................................79 万方数据 VI Contents Abstract ........................................................................................................................ Ⅱ Contents ..................................................................................................................... Ⅵ List of Figures ......................................................................................................... Ⅷ List of Tables ............................................................................................................. XI List of Variables ..................................................................................................... XIII 1 Introduction ............................................................................................................... 1 1.1 Origin and Background ............................................................................................ 1 1.2 Research Status and Problems ................................................................................. 2 1.3 Research Contents and s .............................................................................. 7 1.4 Research Significance .............................................................................................. 7 1.5 Structure of Thesis ................................................................................................... 8 2 Overall Design of Test Plat for Electrical Control System ........................... 9 2.1 Basic Structure and Working Mechanism of Shearer .............................................. 9 2.2 Design of Shearer Bus Control System ................................................................. 11 2.3 Bus Architecture of Shearer Control System ......................................................... 16 2.4 Overall Scheme Design of Shearer Control System Test Plat ....................... 18 2.5 Summary ................................................................................................................ 19 3 Design of Bus Simulation Driver Protocol for Shearer Control System Test Plat ...................................................................................................................... 20 3.1 CAN Bus ................................................................................................................ 20 3.2 CANopen Protocol ................................................................................................. 21 3.3 Research on Master Slave Communication Technology Based on CanFestival Protocol Stack .............................................................................................................. 23 3.4 Establishment of Master Slave Object Dictionary.26 3.5 Four CAN Bus Structure of Shearer Control System.32 3.6 Summary ................................................................................................................ 33 4 Research on Simulation Driving Test Technology of Shearer Real Working Condition .................................................................................................................... 34 4.1 The Overall Design of Shearer Real Condition Simulation System ...................... 34 4.2 Generation of Simulated Conditions ...................................................................... 39 4.3 The Model of Driving System of Coal Mining Machine Test Plat ................ 46 万方数据 VII 4.4 Summary................................................................................................................56 5 Test Experiment of Shearer Control System........................................................57 5.1 Software Design of Test Plat..........................................................................57 5.2 Design of Experiment Plat.............................................................................60 5.3 Experimental Verification......................................................................................61 5.4 Summary................................................................................................................68 6 Summary and Prospect .................................................................................