Abstract: In response to the problems existing in mine monitoring and control, we have carried out scientific and technological research with relevant units, and actively applied existing new technologies applicable to mine monitoring and control, which has effectively ensured mine safety.
Keywords: coal mine; production; monitoring; surveillance
Yanzhou Coal Mining Area of the Modern Monitoring and Controlling Techniques
Bao Xiu-chun Li Jian-feng
(1. Zoucheng senior vocational technical schools, Shandong 273500, China;
2. Yankuang Group Design and Research Institute, Shandong 273500, China)
Abstract： Mine Monitoring and Controlling for the problems was jointly conducted with the relevant scientific and technological breakthroughs, while the positive application of the current application of the existing mine monitoring and control of new technologies, effective protection of the mine's security.
Key words: Coal mine; production; monitoring; Monitor
Since 2000, with the continuous improvement of national requirements for coal mine safety and the needs of enterprise development, large, medium, and small coal mines across my country have successively equipped themselves with mine monitoring and control systems. The installation of these systems has greatly improved the level of mine safety production and the efficiency of safety management. At the same time, it has also placed higher demands on the correct selection, use, and maintenance of this technology, as well as the information management of enterprise safety production. Currently, coal mine safety monitoring systems have multiple functions, including analog quantity, digital quantity, and cumulative quantity acquisition, transmission, storage, processing, display, printing, audible and visual alarms, and control. They are used to monitor underground methane concentration, carbon monoxide concentration, carbon dioxide concentration, oxygen concentration, wind speed, negative pressure, temperature, smoke, power supply status, air door status, air window status, ventilation duct status, local ventilation fan operation, main ventilation fan operation, working voltage, and working current. Furthermore, they have implemented audible and visual alarms for methane exceeding limits, power outages, and methane-powered interlocking control. In recent years, Yanzhou Coal Mining (Group) Co., Ltd. and its subordinate coal mines have carefully analyzed and summarized some problems that existed in mine monitoring and control in the past, and have carried out scientific and technological research with relevant units, achieving a number of fruitful research results. At the same time, they have actively applied existing new technologies applicable to mine monitoring and control, proposed solutions, and implemented them in the mines, effectively ensuring mine safety and achieving good results.
1. Application of centralized monitoring system for large equipment in coal mines
The Dongfeng Shaft of Xinglongzhuang Coal Mine of Yanzhou Coal Mining (Group) Co., Ltd. has achieved centralized monitoring of large equipment. The equipment has sufficient data collection parameters and the user program design is conducive to expansion, creating valuable experience for the future unmanned operation of the machine room.
The centralized monitoring system for large equipment at the Dongfeng Shaft of this mine includes a main monitoring system, a 6kV substation microcomputer protection system, and an industrial television video system. The main monitoring system connects to subsystems for monitoring fans, water pumps, and air compressors. Its monitoring host computer uses an Advantech IPC610 series industrial computer, which, through communication with each subsystem, centrally monitors the operation of all equipment, tracking the operating parameters, working status, and fault alarm information of the air compressor, fan, and water pump subsystems. It can also provide real-time, intuitive simulation displays of system diagrams for large equipment such as air compressors, water pumps, and fans.
A key feature of this control system is the relative independence of each subsystem. It can be remotely controlled via a centralized network or operated independently on-site, without interference between subsystems. Industrial IPCs are used for "high-level monitoring," while high-quality Siemens S7 series PLCs are used for "physical-level" sampling and control. The combined use of these two control and data processing technologies allows for complementary advantages, making them ideal for monitoring large-scale electromechanical equipment. The industrial control computer in the background, the PLC controllers in the front end, and the data acquisition cards for the fans all have watchdog timers in their CPUs, enabling automatic system reset without intervention in the event of a software failure that causes the main unit to crash.
The main monitoring system uses Windows 2000NT as its operating system and KingSCADA 6.02, the most widely used industrial control software in China, which is particularly convenient for software development. The digital recording component of the video system adopts a unique modular design and uses advanced multimedia hardware and software technology. This solves the problems of unclear images, complex management, and high costs that often arise from the repeated use of videotapes in previous monitoring systems. It can perform manual recording, scheduled recording, video movement recording, and recording linked to arming and alarms. It features automatic deletion when full, camera and PTZ control, software anti-crash protection, and automatic recovery after power failure. Its advanced network performance allows image transmission over dedicated data lines, telephone lines, and broadband networks.
2 KJ56 Coal Mine Dispatch and Monitoring System
To meet the actual needs of small and medium-sized coal mines, Shandong University of Science and Technology and Tangcun Coal Mine of Yanzhou Coal Mining (Group) Co., Ltd. have developed a low-cost, highly reliable, simple-structured and easy-to-maintain KJ56 coal mine dispatching and monitoring system, which has good prospects for promotion and application.
The entire system consists of 7 substations and 40 sensors. Measuring parameters include wind speed, gas, current, voltage, equipment operation/shutdown, damper operation/shutdown, steam pressure, air pressure, winch operation/shutdown, and its operating position. The control center of the system is a ground computer, i.e., the system host, which communicates with each substation via a communication interface. The substations are all connected together via a 2-core communication cable and do not communicate with each other. The system host first defines the measuring points of each substation based on the connection ports between the substation and the sensors. The definition includes the number of measuring points, terminal numbers, sequence numbers, and whether the quantity is analog or digital. After definition, the "Initialize" menu is selected to initialize each substation. After successful initialization, the substation stores the defined parameters sent by the host into a non-volatile memory. When a substation experiences a power outage due to a fault and is then restored to power, the microcontroller can automatically retrieve the original system-defined parameters for cyclic monitoring without requiring the system host to re-initialize it.
The KJJ12 communication interface is a communication signal converter connected to the host. It communicates with the host using a standard RS232 interface, and with the substations using an intrinsically safe, two-wire baseband signal. It features optocoupler isolation circuitry, automatic master/slave switching, and communication indication functions, resulting in a low communication error rate. In monitoring systems, the microcontrollers within substations cannot afford to freeze, so a reliable automatic microcontroller reset circuit was designed. During normal operation, the oscillator outputs a positive pulse to the reset circuit at adjustable intervals to reset the microcontroller. However, while the microcontroller is working normally, it continuously outputs a clear pulse to the oscillator, ensuring all oscillator outputs are low. The oscillator only functions normally when the microcontroller freezes.
3. Application of automated monitoring system for water pumps
In underground mine pump rooms, the pump motors need to be frequently started according to changes in water level. The operation is cumbersome, the environment is harsh, the noise is high, the temperature is high, and personnel are prone to fatigue. It is especially dangerous to leave personnel on duty in the event of a flood. The automated pump monitoring system developed by Yanzhou Coal Mining (Group) Co., Ltd.'s Jining No. 3 Coal Mine has reduced the burden on workers, achieved unmanned operation, and laid the foundation for mine-wide network monitoring and digital construction. It also has broad prospects for practical application.
The entire system comprises data acquisition and detection, on-site monitoring and control, and remote monitoring and command, offering both automatic and local operation modes. An industrial computer automatically starts and stops the water pumps based on water level conditions, automatically rotating the pumps and making rational scheduling decisions. The system has overload, undervoltage, leakage, and over-temperature protection functions; when any of these conditions occur or the motor malfunctions, it automatically stops the operation of the pump and simultaneously starts the backup pump. The on-site control center transmits the collected data and scheduling strategies to the ground command center, and can simultaneously display the pump's operating status. The system retains the original manual control mode of the equipment, allowing for normal pump operation under manual control when necessary. Both the system software and client software have a fully Chinese visual interface, allowing users to perform all monitoring operations based on the clear Chinese function displays.
The automated monitoring of pump stations involves specific equipment such as motors, pumps, jet pumps, electric gate valves, solenoid valves, instrument displays, and water level detection. The system operates sequentially through five stages: real-time water level detection, vacuuming and automatic water injection, motor starting and gate valve operation, parameter communication and screen display, and fault prevention and detection. Applying PLC technology to pump stations in underground mines allows for the rational scheduling of pump operation and timely startup based on the principle of "peak shaving and valley filling." This avoids inaccurate manual water level judgments, eliminates frequent manual pump starts, and enables pump startup during off-peak electricity periods, thereby improving the reliability, power efficiency, economic benefits, and modern management level of the pump station.
4. Application of intelligent monitoring terminals in ventilation fan monitoring systems
Mine ventilation fans are crucial equipment for supplying air to underground mines, and their operational status directly impacts the quality of airflow. The Machinery Repair Plant of Yanzhou Coal Mining (Group) Co., Ltd. has developed a mine ventilation fan monitoring system comprised of ST-JK06 series intelligent monitoring terminals. This system can monitor the operating status of the ventilation fans and effectively control the airflow volume based on actual environmental conditions such as air pressure, hazardous gas content, temperature, and humidity. This not only meets the on-site air requirements but also prevents excessive airflow, reducing energy consumption and providing a reliable guarantee for safe production.
The ST-JK06 series intelligent monitoring terminal can not only collect data on hazardous gases and physical parameters such as wind speed, wind pressure, temperature, and humidity at the work site, but also collect data on electrical parameters such as power supply voltage, current, frequency, and power of the ventilation fan. This terminal sends information to the monitoring center, enabling on-site monitoring. The monitoring center can then send control commands to the intelligent monitoring terminal to effectively control the ventilation fan. Based on the sampling principle, this terminal employs a high-performance embedded ARM system and integrates advanced technologies and processes such as DSP, fieldbus, automatic control, high-speed data acquisition, and surface mount technology. This allows for real-time acquisition, linear exchange, calculation, and analysis of various AC and DC electrical parameters. Furthermore, the terminal features analog input/output, digital input/output, keyboard input/LCD display, and other functions.
Given that real-time monitoring of motor operation has become a technical requirement for most users, the ST-JK06 series intelligent monitoring terminal can detect parameters such as motor operating current, voltage, power, and electricity consumption, enabling timely detection of motor malfunctions and preventing motor burnout. Furthermore, this system can not only monitor individual fans but also form a large monitoring network using the ST-JK06 series intelligent monitoring terminals, allowing monitoring of multiple fans via wired communication and GPRS/CDMA wireless communication.
5. A monitoring system for ventilation fans in coal mine shafts has been successfully developed.
The ventilation room of the Xinglongzhuang Coal Mine of Yanzhou Coal Mining (Group) Co., Ltd. has two G4-73-11№25D main ventilation fans installed, responsible for underground ventilation in the east wing of the mine. The original equipment control system consisted of simple control cabinets brought in from the 1970s, which were no longer adequate for safe and efficient production. Therefore, in collaboration with the Shandong Provincial Coal Science Research Institute, they successfully developed a monitoring system for the east ventilation fans, meeting the requirements for monitoring and controlling various key parameters of the fans. Field operation has demonstrated its excellent performance and stable reliability.
The monitoring system for the ventilation fan room in the mine's east shaft consists of one Advantech IPC shared control unit installed in the main control room; three subordinate monitoring units, all installed in the ventilation fan room, are responsible for data acquisition and processing. The core control unit of the subordinate units uses an Atmel 89 series microcontroller, expanded with non-volatile RAM, watchdog circuit, digital output, digital input, analog input, serial communication, and power acquisition units. The main unit monitors online parameters such as voltage, current, power factor, active power, reactive power, front bearing temperature, rear bearing temperature, duct static pressure, duct total pressure, duct dynamic pressure, equipment speed, and fan ventilation volume. By monitoring these parameters, the system dynamically monitors the mine's ventilation system operation, simultaneously monitors the operating efficiency of the running fans online, and allows for full-range technical measurements of the standby fans at any time. The measurement of its wind pressure and air volume adopts intrinsically safe explosion-proof sensors, equipped with input safety barriers, which not only meets the requirements of the "Coal Mine Safety Regulations" for electrical equipment in coal mine ventilation shafts, but also ensures the safety of the microcomputer system.
In addition, an industrial control computer is used for the supporting industrial television video, which utilizes a video capture card and an MPEG4 digital hard disk recording system to monitor the status of the equipment in the ventilation room in real time. It can perform dynamic video recording, timed recording, and alarm-linked recording functions, and can realize network transmission and remote control. It has all-round control functions for camera lenses and pan-tilt units, so as to promptly detect and deal with abnormal working conditions of the equipment and eliminate potential faults as soon as possible.
6. Mining Camera Workbench Controller
Xuzhou Institute of Technology and Nantun Coal Mine of Yanzhou Coal Mining (Group) Co., Ltd. have developed a microcontroller-based mine camera workbench controller, which is mainly used to monitor ore conveyor belts and can control the camera to move up and down and left and right from the central control room to change the monitoring range.
In on-site monitoring, operators in the control room are required to adjust the camera's workbench movement via a computer interface. However, the control room is typically far from the monitoring site, necessitating consideration of control signal transmission. Furthermore, given the numerous monitoring locations (ranging from a dozen to dozens), the control room needs a connection bus and corresponding communication protocol to control these workbench units. This device uses an RS232 to RS485 bus interface to access the communication network. Since the workbench's load consists only of one camera and its protective housing, a low-power electric motor is sufficient. Given the relatively low precision requirements for workbench control, prioritizing reliability, plastic gears can be used in the transmission to reduce equipment costs. The controller's core task is to receive and interpret control commands from the control room and then execute corresponding control actions.
The design of this device only has six valid commands: tilt up, tilt down, turn left, turn right, zoom, and focus, making the corresponding microcontroller program relatively simple to write. The difficulty lies in ensuring the accuracy of RS485 communication. Because RS485 communication uses the same physical channel for both sending and receiving, it is a half-duplex communication mode. This means that only one processor is allowed to remain in sending mode at any given time; otherwise, errors will occur. Since the microcontroller's serial port is full-duplex, during the controller's power-on reset period, the controller must be in full receiving mode. Strict control of the sending and receiving timing is also required; the controller can only respond after detecting that the host has finished sending a command. Tests show that the controller is easy to adjust, operates stably, and provides reliable communication within 1000m, making it suitable for monitoring in mine ore conveying sites.
7. Integrated Automated Monitoring System for Coal Mines Based on iFIX
In response to the relatively backward level of automation and scientific management in my country's coal mines and the common problem of information sharing between various departments, China University of Mining and Technology and Jining No. 3 Coal Mine of Yanzhou Coal Mining (Group) Co., Ltd. have developed a coal mine integrated automation monitoring system based on iFIX. It has successfully realized communication with the lower-level PLC equipment and has great value for widespread application.
The integrated automated monitoring system of Jining No. 3 Coal Mine is designed in two main layers: the information layer and the control layer. The information layer adopts a client/server (C/S) architecture. Workstations act as iFIX clients, providing an interface for operators to send control commands. The server acts as an iFIX server, primarily exchanging real-time data with the production site through a real-time database. It serves as the interface for operators to send commands and uses an SQL Server database to archive important production data. The control layer uses a Control-Net ring network. Control Logix substations located on the ring network control the actual equipment and return control status and information. Furthermore, real-time production information can be viewed through a web server. To improve the reliability of system control, two servers are used for dual-machine redundancy. When one server fails, the other server can immediately take over all its work.
iFIX cannot communicate directly with the underground Control Logix; it must communicate through a corresponding I/O driver. Jining No. 3 Coal Mine utilizes the Intellution Gateway for Server driver, abbreviated as IGS driver. This driver is specifically developed for AB's PLC hardware and boasts extremely fast read speeds. In IGS configuration, first, a data channel must be established, selecting the device model; then, a device name must be created, entering the correct Device ID; finally, a tag must be created, the address represented by the tag being the address of the process hardware. When there is a large amount of monitoring data, establishing multiple channels can avoid the serious consequences of slow or even non-existent data refresh rates.
8. Yangcun Coal Mine Remote Production Video Monitoring System
Yangcun Coal Mine of Yanzhou Coal Mining (Group) Co., Ltd. adheres to the principle of "safety first, prevention foremost," striving to shift its safety production work from passive prevention to source management. The mine has established a comprehensive video surveillance system and a safety monitoring system. Utilizing safety monitoring equipment and cameras, it has achieved remote environmental monitoring, allowing the ground dispatch and command center to directly monitor the underground situation in real time. The combined use of these two systems not only allows for intuitive monitoring and recording of the underground safety production situation, but also, through information fed back from gas sensors, temperature sensors, and other equipment installed underground by the KJ95 safety monitoring system, it can promptly detect potential accidents, preventing them before they occur. Furthermore, it provides effective data for post-accident analysis, offering valuable experience for future safety production.
(1) Main features of remote production video monitoring system.
① Networking. Network video surveillance systems enable image transmission and sharing over a network.
② Scalability. The control components adopt a centralized structure and embedded technology, which can be easily and flexibly expanded, fully ensuring the system's adaptability in the future and minimizing the need for repeated investment.
③Availability and reliability. Utilizing advanced video compression techniques, it features low bandwidth, low latency, full-duplex operation, and high-definition playback.
④ Mutual redundancy backup. Both the management server and the recording server support mutual redundancy backup, ensuring the system's stability and reliability with ample technical support.
(2) Build a comprehensive remote production video monitoring system.
The video capture equipment is installed in the main transportation and pedestrian roadways and the main mining face of the mine.
① Establish an emergency command and dispatch system for all relevant departments. After an accident occurs, the system can automatically convene an emergency meeting with leaders and relevant departments via SMS notification as soon as possible, and import monitoring images into the meeting room for rapid decision-making to initiate emergency procedures in order to prevent and reduce casualties.
② Establish a video conferencing system for the production site. This will facilitate education and training on underground safety production by mine leaders and relevant industry departments, and improve the safety awareness and work capabilities of staff.
③ Establish a professional technical management team. This facilitates the correct operation of the monitoring system, timely repair of various faults, and ensures the normal operation of the system.
④ Establish a strict performance evaluation system. Implement rewards and penalties based on the above aspects to ensure the quality of the monitoring system's operation.
⑤ Establish an effective joint prevention and mutual promotion organization. Single-party video surveillance can only manage the uploading of video images. It also needs to be organically combined with the monitoring and control systems of other units in the mine so that the dispatch and command system can grasp information from all aspects of the mine.
9. Research on Multimedia Network Monitoring System for Coal Preparation Plant
The Xinglongzhuang Coal Mine Coal Preparation Plant of Yanzhou Coal Mining (Group) Co., Ltd. has successively completed several projects, including the "Microcomputer Monitoring and Management Control System for Coal Preparation Plant," the "Fiber Optic Industrial Television Monitoring System," the "Coal Quality Analysis Computer Information Feedback Network System," and the "Equipment Fault Diagnosis System." However, these systems are independent of each other and cannot achieve interactive sharing of information resources. Therefore, they conducted a "Feasibility Study on the Implementation of a Multimedia Network Monitoring System for the Xinglongzhuang Coal Mine Coal Preparation Plant," concluding that the plant is ready to establish such a system.
The Xinglongzhuang Coal Preparation Plant's multimedia network monitoring system is a new processing mode that integrates the plant's microcomputer monitoring and management information system, production information feedback system, equipment fault diagnosis system, dynamic graphic monitoring of production processes, fiber optic industrial television images, and audio information. It can transmit image and data management information to relevant plant leaders and workshops, providing a convenient and fast means for correctly and quickly directing production and timely and accurately adjusting and analyzing the production structure.
The design principles of the multimedia network monitoring system for the Xinglongzhuang Coal Mine's coal preparation plant are: to fully integrate the existing microcomputer monitoring and management system with various computer information applications, to be compatible with and include existing equipment investments, and to protect existing hardware and software resources; to fully utilize and apply existing advanced multimedia network technologies, while considering future business needs and technological developments, facilitating system expansion and maintaining technological continuity; and to minimize system costs and improve the system's performance-price ratio while adopting advanced technologies. The system's configuration and functions are as follows: First, a multimedia information processing center is established, equipped with multimedia program editing, creation, and playback production equipment; multimedia workstations are set up in the plant leadership and workshop offices, allowing for the sharing of dynamic simulation diagrams of plant production, industrial television images, CD-ROM playback resources, and closed-circuit television programs in various offices through the multimedia network monitoring system; it connects with higher-level units such as the mine dispatcher and bureau dispatcher via fiber optic cables to share resources; and through organic integration with the Internet, it lays the foundation for realizing a CIMS (Corporate Identity System) for the coal preparation plant.
10. Ground-based waste rock disposal multimedia locomotive monitoring system
The ground-based multimedia locomotive monitoring system selected by the Dongtan Coal Mine of Yanzhou Coal Mining (Group) Co., Ltd. not only ensures locomotive speed but also guarantees transportation safety, effectively solving the problem of locomotive throughput in the transportation yard and creating significant benefits.
The system consists of indoor centralized control equipment and field signaling equipment. The signaling equipment controlling locomotive operation is located on-site, including electric switch machines, signals, sensors, and cameras. The switch machines change the locomotive's direction, the signals indicate the locomotive's start and stop, the sensors track and monitor the locomotive's position, and the cameras monitor train occupancy in the depot. The indoor equipment consists of an operation control console, relay cabinet, power supply cabinet, lightning protection cabinet, and a large-screen display. The system's main unit, the 984-385 control software, adopts a modular structure, with the entire program divided into two sections. The first section contains the core components: system reset, sensor short-circuit detection, and route status control. This program controls route query, occupancy/unlocking transitions, signal opening, some prompt signals, and automatic control signals for the switch machines. The second section includes route sending and unlocking procedures, electric switch machine control and alarm procedures, and data transmission procedures.
The system has the following features: it uses a programmable logic controller (PLC) of internationally advanced level from the United States as the system control host, enabling three control modes: programmable control, centralized control, and manual operation; it provides image monitoring of the operation of the waste rock washing bin, waste rock sorting bin, level crossing, and hoisting cage, displaying information such as locomotive number, train position, route occupancy, signal display, and switch machine tip position; it provides audible and visual alarms for broken signal bulbs, switch machine tip misalignment, and sensor electrical faults; when a locomotive runs a red light, a red light strip flashes in the red light area; it counts the number of waste rock cars in the waste rock washing bin, waste rock sorting bin, level crossing, and hoisting cage, and prints various data for vehicle dispatching and management according to production needs; it has interfaces for connecting to the mine network and underground locomotive monitoring system; and the gap rail sensor used for the first time has shockproof, waterproof, and impact-resistant functions, with stable and reliable performance.
11. CAN Bus-Based Sonar Data Acquisition System for Autonomous Mobile Robots
To meet the real-time navigation needs of autonomous mobile robots, the Beisu Coal Mine of Yanzhou Coal Mining (Group) Co., Ltd. proposed a CAN bus-based sonar data acquisition system for mobile robots. Considering the working characteristics of autonomous mobile robots, a multi-sonar sensor data acquisition system was designed using CAN bus technology, realizing networked robot data acquisition, reducing the number of system connections, and improving system maintainability. The CAN bus communication protocol between the system and the industrial control computer was also determined, and the system hardware block diagram and software flowchart are provided. Experiments show that the system has high practical value and high reliability and real-time performance.
Autonomous mobile robots are robots adapted to work in complex, unstructured environments. The newly developed sonar-guided autonomous mobile robot employs a four-wheel or two-wheel drive differential steering system, with each drive wheel independently driven by a DC servo motor. Its hardware system mainly consists of a sonar data acquisition system, an industrial computer main control system, and a drive motor measurement and control system. The sonar data acquisition system includes a Polaroid 6500 sonar sensor, a data acquisition board, and a CAN bus adapter card; the industrial computer main control system includes an industrial computer and various peripheral devices; and the drive motor measurement and control system mainly consists of an EPOS motion controller, encoders, reducers, and DC servo motors. The EPOS is a modular digital servo controller with multiple motion control modes, including torque, speed, and position. Based on the CA Nopen protocol, it communicates with the main control computer via a CAN bus and can independently control single or multi-axis DC servo systems. All axes can achieve real-time and synchronous motion control via the CAN bus.
Environmental information is transmitted to the industrial control computer via a sonar data acquisition system. The data processing module in the industrial control computer identifies the environmental information, and the main control microcomputer obtains the current motion rules by querying the expert system and issues corresponding commands to the EPOS motion controller. Finally, the EPOS motion controller controls the drive motors according to the received instructions to achieve obstacle avoidance and navigation for the robot. The system operates stably and reliably at a baud rate of 1 Mbps, meeting the needs of practical robot applications.
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