在综采工作中，刮板输送机作为煤炭运输的关键设备，同时兼具采煤机运行轨道和液压支架推溜支点的多重功能。刮板输送机直线度的实时精确测量是实现工作面智能化开采的重要技术基础。然而，现有测量方法存在测量不足、实时性差、成本高昂及复杂工况适应性差等局限性。针对上述问题，本文提出了一种融合采煤机位姿与液压支架推移量的刮板输送机直线度动态测量方法，研制了具有高度集成化和智能化特点的测量装置，并构建了完整的刮板输送机直线度测量系统。论文主要研究包括：

（1）基于综采“三机”协同工作原理，研究分析了刮板机直线度变化规律和影响因素，并结合“三机”之间的约束关系，提出了一种融合采煤机位姿和支架推移量的刮板机直线度测量方法。确定了由采煤机位姿测量装置、液压支架推移量测量装置和上位机组成的刮板机直线度测量系统总体方案。通过坐标转换和空间坐标矢量累加法，建立了采煤机位姿解算模型。考虑支架底座姿态角并基于投影原理，建立液压支架推移量解算模型。结合采煤机位姿和支架推移量建立刮板输送机直线度求解模型。

（2）研究确定了采煤机姿态、位置、支架推移量等参数的信号获取与处理方法。由安装于采煤机机身中心处的惯导元件MPU9250获取机身姿态角信息，由安装于采煤机行走部高速齿轮轴处的磁敏角度元件TLE5012B获取旋转角度与圈数信息，经计算得到采煤机行走里程信息。由安装于支架底座处的MPU6050获取底座姿态角信息，由红外测距传感器VL5300获取支架推移杆长度信息。针对惯导存在累积误差的问题，采用姿态航向参考系统（AHRS）互补滤波算法矫正采煤机的姿态角，采用卡尔曼滤波矫正液压支架底座姿态角。在滑动窗口内使用Kalman-RTS方法对采煤机位姿信号进行平滑处理，以减少采煤机截割振动对其的影响。

（3）采用DSP（TMS320F28335）作为主控芯片，结合上述感知元件，分别研制采煤机行走里程传感器、机身姿态传感器和液压支架底座姿态传感器。其中，采煤机行走里程传感器和姿态传感器共同组成采煤机位姿测量装置，液压支架底座姿态传感器通过SCI接口联合红外测距传感器组成液压支架推移量测量装置。DSP通过IIC和SSC与MPU9250、MPU6050和与TLE5012B进行数据传输。基于解算模型和信号处理方法，开发了数据采集、姿态角滤波、行走里程解算、采煤机位姿解算与平滑和推移量解算等程序。采用LabVIEW开发了融合采煤机位姿和支架推移量信息的刮板机直线度上位机程求解程序。

（4）制定实验方案，搭建实验平台完成了刮板输送机直线度测量系统及相关装置的功能和性能评估实验，并建立了刮板机直线度误差分析模型。实验结果表明：采煤机俯仰角、横滚角、航向角和旋转角度的最大绝对误差分别是0.07°、0.07°、0.20°、0.12°，平均相对误差分别是0.25%、0.26%、1.05%、0.49%。液压支架俯仰角、横滚角、航向角和推移量的最大绝对误差分别是0.12°、0.10°、0.13°和2.3mm，平均相对误差分别是3.82%、3.02%、4.65%、0.44%。在1.8m长的轨道模拟刮板输送机运动，并以推移步距为10cm，进行直线度测量的X轴和Y轴的最大绝对误差分别为0.74mm、0.08mm，平均相对误差2.43%、0.44%。

In fully mechanized mining, the scraper conveyor, as a key equipment for coal transportation, also serves multiple functions such as the running track for the shearer and the push point for the hydraulic support. The real-time and precise measurement of the scraper conveyor's straightness is an important technical foundation for achieving intelligent mining in the working face. However, the existing measurement methods have limitations such as insufficient measurement, poor real-time performance, high cost, and poor adaptability to complex working conditions. To address these issues, this paper proposes a dynamic measurement method for the straightness of the scraper conveyor that integrates the position and posture of the shearer with the push amount of the hydraulic support. A highly integrated and intelligent measurement device was developed, and a complete measurement system for the straightness of the scraper conveyor was constructed. The main research contents of this paper include:

(1)Based on the collaborative working principle of the "three machines" in fully mechanized mining, the variation law and influencing factors of the straightness of the scraper conveyor were studied and analyzed. Combined with the constraint relationship among the "three machines", a measurement method for the straightness of the scraper conveyor that integrates the position and posture of the shearer and the push amount of the support was proposed. The overall scheme of the scraper conveyor straightness measurement system composed of the shearer position and posture measurement device, the hydraulic support push amount measurement device and the upper computer was determined. Through coordinate transformation and spatial coordinate vector accumulation method, the shearer position and posture solution model was established. Considering the attitude angle of the support base and based on the projection principle, the hydraulic support push amount solution model was established. Combined with the shearer position and posture and the support push amount, the solution model of the scraper conveyor straightness was established.

(2)The research has determined the signal acquisition and processing methods for parameters such as the attitude, position of the coal shearer and the amount of support advancement. The attitude angle information of the coal shearer body is obtained by the inertial navigation component MPU9250 installed at the center of the coal shearer body, and the rotation angle and number of turns information are obtained by the magnetic sensitive angle component TLE5012B installed at the high-speed gear shaft of the coal shearer's traveling part. The traveling distance of the coal shearer is calculated. The attitude angle information of the support base is obtained by the MEMS installed at the support base, and the length information of the support advancement rod is obtained by the infrared distance sensor VL5300. To address the cumulative error problem of inertial navigation, the attitude angle of the coal shearer is corrected by the attitude and heading reference system (AHRS) complementary filter algorithm, and the attitude angle of the hydraulic support base is corrected by the Kalman filter. Within the sliding window, the Kalman-RTS method is used to smooth the position and attitude signals of the coal shearer to reduce the influence of the cutting vibration of the coal shearer.

(3)The DSP (TMS320F28335) is used as the main control chip, combined with the aforementioned sensing elements to develop a walking distance sensor for the coal cutter, an attitude angle sensor, and an attitude angle sensor for the hydraulic support base. The walking distance sensor and the attitude angle sensor together form the equipment for measuring the position of the coal cutter. The attitude angle sensor for the hydraulic support base, in combination with an infrared distance sensor via an SCI interface, constitutes the device for measuring the translation amount of the hydraulic support. The DSP communicates with the MPU9250, MPU6050, and TLE5012B for data transmission via IIC and SSC protocols. Based on the calculation model and signal processing method, programs have been developed for data acquisition, attitude angle filtering, walking distance calculation, position calculation and smoothing for the coal cutter, and translation amount calculations. A LabVIEW-based upper computer program has been developed to solve the linearity of the scraper by integrating information from the coal cutter's position and the support translation amount.

(4)An experimental plan was developed, and an experimental platform was built to complete the functional and performance evaluation experiments of the scraper conveyor linearity measurement system and related devices. Additionally, a linearity error analysis model for the scraper was established. The experimental results indicated that the maximum absolute errors for the pitch angle, roll angle, yaw angle, and rotation angle of the coal cutter were 0.07°, 0.07°, 0.20°, and 0.12°, respectively, with average relative errors of 0.25%, 0.26%, 1.05%, and 0.49%. For the hydraulic support, the maximum absolute errors for the pitch angle, roll angle, yaw angle, and translation amount were 0.12°, 0.10°, 0.13°, and 2.3 mm, respectively, with average relative errors of 3.82%, 3.02%, 4.65%, and 0.44%. In a 1.8 m long track simulating the movement of the scraper conveyor, linearity measurements were taken in the X and Y axes at a translation step of 10 cm, yielding maximum absolute errors of 0.74 mm and 0.08 mm, respectively, with average relative errors of 2.43% and 0.44%.

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