| Coal is the main source of China. The healthy development of coal industry is related to our energy security and sustainable economic development. Hydraulic support is the crucial equipment of fully mechanized mining of coal production. Reliable remote monitoring and scheduling are the important guarantee of fully mechanized mining and safety production. But at present electro-hydraulic control technology of Support at home is still at a low level. It cannot visually reflect the working condition of hydraulic support and is unable to timely detect the supporting performance and predict the failure. It also cannot adjust the operating parameters of hydraulic support and do remote manual intervention when necessary. Therefore, in this dissertation, the virtual reality technology is put forward which can be used for the detection and control of hydraulic support. It not only can achieve remote monitoring and scheduling like on the scene,but also can pre-operate by forecasting hydraulic support performance and faults. The key theories and technologies like hydraulic support movement, mechanical properties, adaptability analysis and system architecture which are suitable for Hydraulic Support remote virtual monitoring are deeply studied in this dissertation.Based on parallel mechanism theory,2-DOF positive and inverse kinematics mathematical models, which established the main body of hydraulic support of both two-leg shield and four-leg chock-shield, are studied in this dissertation. The intellectual solving strategy,which used hybrid genetic algorithm,is proposed to solve the nonlinear model rapidly. The limitation of single freedom kinematics model, which traditionally used in the support design stage, is overcome. Dynamic resolution of hydraulic support movement poses with column and equilibrium jack (four-leg chock-shield hydraulic support as front and back columns) dual-drive components is achieved. It provides a theoretical basis to the virtual hydraulic support inverse structure and motion drive in virtual reality, and offers a new way to the study of hydraulic support mechanics and adaptability.On the basis of in-depth analysis of "voussoir beam" key pieces surrounding rock control theory, positive and inverse mathematical models for hydraulic support mechanics are established using hydraulic support 2-DOF kinematics model. It figures out that hydraulic support bearing capacity is not only the vertical bearing capacity, but also concluding the horizontal bearing property and the torque bearing property. The adaptability of hydraulic support such as bearing capacities of different postures and different loading positions is discussed in this dissertation. The theory model which is related to support stiffness and columns and jack stiffness is proposed, as well as the relationship between support stiffness and top beam load distribution. It provides a theoretical basis for the hydraulic support performance prediction and monitoring, and establishes the theoretical foundation for the further stress analysis of hydraulic support 3D force system and structural component.The hyperstatic problem of hydraulic support 3D mechanical model is solved by analyzing the spatial stress relationship and introducing the declination deformation coefficient of top beam. Hinge-force of each support component can be quickly solved. Quasi membrane method, series analytic method, single part finite element analytic method and entire parts finite element analytic method are used to solve by programming and do finite element simulation to the support structural component stress. Through the analysis and comparison, quasi membrane method is established to be the solution algorithm of the support stress real-time monitoring. The single finite element analysis is the prediction analysis algorithm of the support pre-operation. Faults and safety problems,which caused by forecasting excessive loads of support structural components being not available because of using resistance strain gage to measure stress impracticably in the harsh environment underground,will be solved.After deeply analysing the performance test standard of the hydraulic support, technical indicators, structures and the control schemes of 30000kN Hydraulic support performance testing bed are designed jointly with Zhengzhou Coal Mine Machinery Co., Ltd. The manufacture, installation and commissioning of 30000kN Hydraulic support performance testing has been completed. The performance indexes of the testing are domestic leading and with international. Performance test and stress test of ZY10800/28/63 Hydraulic Support have been done on the test bed. By comparing experimental data and calculated data, effectiveness of hydraulic support movement and mechanical model theory has been verified. The development of Hydraulic support testing monitoring system provides technical preparations to the scheme design and project's implement of the hydraulic support monitoring system.Function requirements and means of realization of hydraulic support remote monitoring system have been analyzed in detail. The safe and reliable redundant communication network which is composed of wireless MESH networks and 1000M fiber industrial ring network is proposed. The hydraulic support remote virtual monitoring system hierarchical structure framework of logical functions is constructed. The integrated development scheme of hydraulic support monitoring platform software system based on virtual reality environments and the interface technology that seamless integrating kinematics, mechanics, virtual reality and other submodule developed by MATLAB, Virtools, NX Nastran, VC++.NET, VC#.NET and other softwares is established. Hydraulic support remote virtual monitoring platform has already been developed basically, which can achieve the main functions of virtual motion display, supporting performance evaluation, fault prediction, pre-operation and remote monitoring of hydraulic support. |
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