Design and Application of a Digital Direct-Drive Electro-Hydraulic Control System for Coal Mine Drilling Rigs
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摘要: 针对常规煤矿钻机电控系统集成度低、现场调试周期长、故障定位效率低等问题，设计一种煤矿钻机用数字直驱式电液控制系统. 采用分布式架构，构建双通道隔离CAN总线通信网络，开发数据服务与边缘计算模块，多源异构数据采集板和基于数字阀的驱动电路；制定专用通信协议，开发总线在线监测、传感器故障诊断、变值触发式控制指令下发算法；融合远程组网与IAP远程升级技术，实现系统远程调试与维护. 将系统应用于多种矿用钻机，与传统电液控制系统相比，平均调试周期缩短约50%，非电源短路情况下的常规电控系统故障识别率达100%，售后服务频次降低约50%. 有效提升了电控钻机数字化水平和系统可维护性，为矿用钻机数字化升级提供了一套可行的方案.Abstract: To address the issues of low integration, lengthy on-site commissioning cycles, and inefficient fault localization in conventional electric control systems for coal mine drilling rigs, a digital direct-drive electro-hydraulic control system for coal mine drilling rigs is designed. A distributed architecture is adopted, and a dual-channel isolated CAN bus communication network is constructed. Data service and edge computing modules, multi-source heterogeneous data acquisition boards, and digital valve-based drive circuits are developed. A dedicated communication protocol is established, along with algorithms for bus online monitoring, sensor fault diagnosis, and variable-triggered control command transmission. Remote networking and IAP remote upgrade technologies are integrated to enable remote system commissioning and maintenance. The system is applied to various types of mine drilling rigs. Compared with traditional electro-hydraulic control systems, the average commissioning cycle is shortened by approximately 50%, the fault identification rate for conventional electric control systems under non-power-short-circuit conditions reaches 100%, and after-sales service frequency is reduced by about 50%. This study effectively enhances the digitalization level and system maintainability of electrically controlled drilling rigs, offering a feasible solution for the digital upgrade of mining drilling rigs.
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图 1 数字直驱式电液控制系统总体方案
Fig. 1. Overall scheme of the digital direct-drive electro-hydraulic control system
图 3 隔离CAN总线与RS485总线电路原理图
a.RS485总线电路；b.CAN总线电路
Fig. 3. Schematic diagram of the isolated CAN bus and RS485 bus circuits
图 4 Linux核心板外围主要电路接口
Fig. 4. Main peripheral circuit interfaces of the Linux core board
图 5 采集器与控制器三维模型
a. 采集器三维模型（1防水航插，2采集器机芯组件，3门盖密封条，4采集器壳体，5门盖，6按钮，7触摸屏）；b.控制器三维模型（1控制器机芯组件，2电缆引入装置，3防爆壳体，4双路本安电源，5驱动板，6开关电源，7门盖）
Fig. 5. Three-dimensional model of the collector and controller
图 7 变值触发式控制指令下发算法框图
Fig. 7. Algorithm flowchart for variable-value triggered control command issuing algorithm
图 10 ZDY10000LDK型窄体式遥控定向钻机
Fig. 10. ZDY10000LDK narrow-body remote-controlled directional drilling rig
图 11 ZDY10000LDK钻机电液控制系统组成示意图
Fig. 11. Schematic diagram of the ZDY10000LDK drilling rig electro-hydraulic control system composition
图 12 远程组网与现场设备示意图
Fig. 12. Schematic diagram of remote networking and on-site equipment
图 13 搭载不同电液控制系统的钻机调试周期对比
Fig. 13. Comparison of commissioning cycles of drilling rigs with different electro-hydraulic control systems
图 14 搭载不同系统的钻机售后服务频次对比
Fig. 14. Comparison of after-sales service frequency of drilling rigs with different systems
表 1 多源数据采集板接口类型与数量
Table 1. Interface types and quantities for multi-source data acquisition board
接口类型 符号 数量 备注 电流量采集接口 AI 11路 电压量采集接口 UI 11路 可复用为AI或DI 电阻量采集接口 RI 2路 开关量采集接口 DI 8路 CAN总线接口 CAN 2路 隔离设计 RS485总线接口 RS485 1路 隔离设计 
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表 2 驱动板接口类型与数量
Table 2. Interface types and quantities of the drive board
接口类型 符号 数量 备注 CAN总线接口 CAN1 1路 本安 CAN总线接口 CAN2 1路 隔爆 PWM输出接口 PWM 6路 隔爆
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表 3 数据采集系统通讯协议
Table 3. Communication protocol of the data acquisition system
CAN ID 数据位 D0 D1 D2 D3 D4 D5 D6 D7 0x200 AI个数 UI个数 RI个数 CAN RS485 0x311 AI1 AI2 AI3 AI4 0x312 AI5 AI6 AI7 AI8 0x313 AI9 AI10 AI11 RI1 0x314 UI1 UI2 UI3 UI4 0x315 UI5 UI6 UI7 UI8 0x316 UI9 UI10 UI11 RI2 0x317 DI SDI1 SDI2 SDI3 0x318 CAN120 CAN121 CAN123 CAN124 0x319 CAN125 CAN126 CAN127 CAN128 0x31A RS485-1 RS485-2 RS485-3 总线传感器故障码 0x31B 电流量短路故障码 电流量断路故障码 电压量短路故障码 电压量断路故障码
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表 4 防爆数字阀CAN总线通信协议
Table 4. CAN bus communication protocol of the explosion-proof digital valve
ID 数据位 帧类型 D0 D1 D2 D3 0x180+ID 0x08 0x00 [-1 000，1 000] 反馈帧 0x200+ID 0x07 0x00 [-1 000，1 000] 指令帧
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表 5 驱动板通讯协议
Table 5. Communication protocol of the drive board
本安CAN1 ID 数据位 隔爆CAN2 D0 D1 D2 D3 D4 D5 D6 D7 接收 0x401 PWM1 PWM2 PWM3 PWM4 PWM5 PWM6 PF 无 发送 0x629 RPWM1 RPWM2 RPWM3 RPWM4 RPWM5 RPWM6 PS 接收 0x201 0x07 0x00 [-1 000，1 000] 无 转发 接收 0x202 0x07 0x00 [-1 000，1 000] 无 转发 接收 …… 0x07 0x00 [-1 000，1 000] 无 转发 转发 0x181 0x08 0x00 [-1 000，1 000] 无 接收 转发 0x182 0x08 0x00 [-1 000，1 000] 无 接收 转发 …… 0x08 0x00 [-1 000，1 000] 无 接收
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表 6 电控系统故障识别诊断统计
Table 6. Statistics of electronic control system fault identification and diagnosis
故障类别 出现次数 识别次数 识别准确率 本安型编码器通信中断 48 48 100% 拉绳位移传感器通信中断 52 52 100% 遥控器通信链路超时 27 27 100% 遥控器电源短路 6 0 0 CAN总线传感器短路 24 24 100% 数字阀离线 26 26 100% 压力传感器断路 38 38 100% 压力传感器短路 16 16 100% 采集板离线 21 21 100% 驱动板离线 16 16 100%
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