智能化综采工作面安装了大量固定传感器,但依然存在监控盲区和监控滞后的问题。引入巡检机器人技术,对综采工作面的全覆盖和实时监控,是智能化开采的必要技术手段。从国家宏观政策和智能开采技术2个层面,分析了智能开采对综采巡检机器人的迫切需求,根据综采工作面巡检机器人的发展现状,总结了综采工作面应用机器人需要解决的柔性轨道、移动通信无缝漫游、远程控制和自主操作等技术难题。通过研究用于综采巡检机器人的跨式柔性轨道、行走控制、移动通信、移动精确定位、惯性导航、动态图像采集和控制采煤机调高等7项关键技术,提出了建立巡检机器人的感知理论技术装备体系、研究井下机器人动力供应技术、建立高性能的无缝漫游移动通信系统、开发超高清热成像和毫米波对综采生产时的三维实景呈现技术、研制集成视觉雷达和煤层探测的超前探测机载装置等5个重点研究方向。在薄煤层综采工作面进行了工业试验,研制的巡检机器人搭载三维激光雷达和惯性导航系统,沿采煤机电缆槽上铺设的轨道边行走边检测,达到了60 m/min的最大巡检速度,实现了双频WiFi零切换的无缝漫游高速通信,根据机载激光雷达扫描和惯性导航系统建立了综采工作面三维截割地质模型,进行了巡检模式下的智能割煤工艺试验,工作面直线度检测和找直偏差不超过150 mm,验证了巡检机器人能够为智能开采提供安全、高效的技术保障。

A large number of fixed sensors are installed on the intelligent fully-mechanized mining face, but there are still disadvantages of monitoring blind spots and monitoring lag. The introduction of inspection robot technology to conduct full-coverage real-time monitoring of the fully-mechanized mining face is a necessary technical means for intelligent mining. At the two levels of national macro policy and intelligent mining technology, the urgent need for intelligent mining for inspection robots for fully-mechanized mining is analyzed. According to the development status of inspection robots for fully-mechanized working face, the technical problems such as flexible track, mobile communication seamless roaming, remote control and autonomous operation that need to be solved by robots in fully-mechanized mining face are summarized. Through the research of seven key technologies such as straddle flexible track, walking control, mobile communication, precise positioning of movement, inertial navigation, dynamic image acquisition and height adjustment of coal shearer of fully mining inspection robots, the following five key research directions are put forward: establishing the perception theory and technical equipment system of inspection robots; studying the power supply technology of underground robots; establishing a high-performance seamless roaming mobile communication system; developing ultra-high-definition thermal imaging and millimeter wave for comprehensive mining production 3D real-time presentation technology and development of an advanced detection airborne device that integrates visual radar and coal seam detection. Industrial tests were carried out on fully-mechanized coal mining faces of thin coal seam and the inspection robot equipped with 3D LiDAR and inertial navigation system has reached the maximum inspection speed of 60 m/min along the track laid on the cable channel of shearer, and realized the seamless roaming high-speed communication with dual-frequency WiFi with zero switching. Based on the boarded LiDAR scanning and inertial navigation system, a 3D cutting geological model of fully-mechanized mining face was established, and an intelligent coal cutting process test in the inspection mode was carried out. The straightness detection and alignment deviation of working face did not exceed 150mm, which verified that the inspection robot could provide a safe and efficient technical means for intelligent mining.

0 引言

1 智能开采对综采机器人的需求

   1.1 国家支持煤炭开采智能化应用机器人技术

   1.2 综采巡检机器人发展中的问题

   1.3 综采工作面巡检机器人研发现状

2 综采巡检机器人技术体系

   2.1 巡检机器人技术体系

   2.2 综采巡检机器人技术研究重点方向

3 综采巡检机器人关键技术

   3.1 跨式柔性轨道技术

   3.2 行走控制技术

   3.3 通信网络体系技术

   3.4 移动精确定位技术

   3.5 惯性导航技术

   3.6 巡检动态图像采集技术

   3.7 综采巡检机器人控制采煤机调高技术

4 巡检机器人应用情况

   4.1 巡检无缝漫游测试

   4.2 移动扫描工作面三维地质模型

   4.3 割煤工艺智能化流程

5 结论