煤矿巷道顶板离层自动监测系统设计
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摘要
我国是世界上最大的煤炭生产国和消费国,煤炭作为主要能源的格局在今后50年内不会改变。但长期以来,煤矿安全问题一直是制约煤炭工业发展的重要因素。顶板问题是煤矿安全问题的一个重要部分,监测顶板的状态,研究顶板的变化规律,对顶板进行及时支护,可以有效确保顶板安全,减少生产过程中的安全隐患。本课题的主要任务是设计一种适合井下使用的巷道顶板离层在线监测系统,实时监测巷道顶板变化,记录顶板变化数据,并提供基本的数据分析,为巷道顶板支护工作提供数据依据。
本文研究的主要内容包括位移传感器设计、采集分站设计、传输分站设计、远程数据传输接口设计和上位机组态软件设计。并通过WEB实现数据在局域网内的共享,通过OPC实现与其他系统对接。
位移传感器：通过高精度齿轮的旋转,触发光电开关,输出电信号。信号经过HEF40106BP整形后,生成标准的方波脉冲,输出至采集分站。
采集分站：实现对传感器信号的实时采集、存储、显示,并通过CAN总线与传输分站进行数据通信。采集分站支持PS／2键盘接口,可以通过PS／2键盘对采集分站进行参数设置。采集分站主板芯片采用PIC18F6585单片机,传感器信号采集及CAN通讯部分采用中断方式进行响应,对传感器信号采集优先处理,确保信号采集的实时性。
传输分站：实现与所有采集分站之间的数据通讯,对所有的采集分站进行巡检,现场显示各采集分站的当前数据,并通过单模光纤模块实现数据的远程传输。传输分站主板芯片也采用PIC18F6585单片机,通过对单片机I／O引脚的控制,实现液晶显示、I2C存储、CAN通讯、串口通讯等功能。
远程数据传输接口：传输接口核心采用MWF101-S单模光纤模块,光口通过单模光纤与井下传输分站的光纤模块连接,RS-232接口通过RS-232连接线与计算机RS-232接口连接。
上位机组态软件：上位机组态软件采用组态王6.52平台进行开发,主要包括人机界面、SQL Server数据库、WEB发布、OPC服务器等方面。良好的人机界面方便操作人员比较直观的观察数据,进行相关的数据分析以及报表打印等操作。SQL Server数据库用于保存在线接收的数据,供报表查询使用。WEB发布实现数据在局域网内的共享。OPC服务器使系统可以方便的与其他系统对接,实现数据共享。
系统优化设计：主要对系统的功耗和稳定性进行优化,从硬件的选型到系统运行中的一些降低功耗的设计,确保系统在电源功率一定的条件下,可以稳定的工作。通过设置软件陷阱、看门狗等方法,提高单片机程序运行的稳定性,防止程序跑飞。
本课题的创新点主要包括：一、根据光电开关的工作原理,将钢丝绳的机械位移转化成电脉冲信号,通过脉冲计数,反应出离层的实际值。二、通过CAN总线技术,实现对井下巷道顶板的长距离分布式实时监测。CAN总线技术的引入方便系统进行扩展,在电源功耗允许的条件下,系统可以根据巷道的长度自由组合。
China is the largest producer and consumer of coal in the world, the situation coal is our primary energy which will not change in the next 50 years. Coal mine safety has been an important factor of constraining development of coal industry for a long time. Roof problem is an important part of the coal mine safety problems. Monitoring the status of the roof, studying the law of the roof change, strengthening the roof in time, can ensure the roof safety effectively and reduce the security risk in production process. The main task of this dissertation is to design a Monitoring System on-line of roof separation that used in roadway underground. It's used in monitoring changes of roof timely, recording data of the roof changes, providing basic data analysis, and providing data basis for strengthening the roadway roof.
The main work of this dissertation includes displacement sensor design, collection substation design, transmission substation design, data transfer interface for long distance design, host computer congfiguration software design. Data is shared through web in local area network, and is docked with other system through OPC.
Displacement sensor:outputs electrical signal through photoelectric switch which is triggered by the high-accuracy gear wheel revolves. Signal is integered by HEF40106BP, and output standard square-wave pulse to collected substation.
Collectiont substation:achieves the signal collection real-time from sensor, storage, display, and data communication with transmitted substation by CAN bus. The collected substation supports PS/2 interface. Parameter of the collected substation can be set through PS/2 keyboard. The MCU of the collected substation's mainbaord is PIC18F6585, signal collection of sensor and CAN bus transmission are responsed by interruption. Priority processing of the sensor's signal can make sure the real-time of the signal's collection.
Transmission substation:achieves the data communication with all collected substations, loop checking for all collected substations, field showing the currunt data of every collected substation, and data communication for long distance by single mode fiber. The MCU of the transmitted substation's mainbaord is PIC18F6585 too. Trough the I/O pins'controlled of the MCU, to achieve LCD, I2C memory, CAN bus communication, serial communication and other functions.
Data transfer interface for long distance:the core is a MWF101-S SMF Module. It's connected with the SMF Module in transmitted substation underground by SMF, and connected with host computer by RS-232.
Host computer congfiguration software:it's developed based on Kingview 6.52. It includes man-machine interface, SQL Server Database, Web Publishing, OPC Server, etc. Good man-machine interface makes for operator to observe data intuitively, to do data analysisi, report printing and other operations. SQL Server Database is used for saving data that received on-line, and supplying for report query. Data is shared in LAN by Web Publishing and shared with other system by OPC Server.
System optimization design:it's mainly for system's power and stability. From hardware's selection to low power design in system's running, it makes sure the system running stably under a certain power range. Software trap and WDT can improve the stability of the program and prevent the program from losing control.
The main points of innovation of this dissertation includes:firstly, according to the principle of photoelectric switch, machinery displacement of steel wire rope is converted into electrical pulses. The count of the electrical pulses is the active value of separation. Secondly, achieving distributed monitoring of roadway roof underground for long distance through CAN bus. Because of the CAN bus is used, the system can be combined freely according to the length of roadway within the framework of the power.
本文研究的主要内容包括位移传感器设计、采集分站设计、传输分站设计、远程数据传输接口设计和上位机组态软件设计。并通过WEB实现数据在局域网内的共享,通过OPC实现与其他系统对接。
位移传感器：通过高精度齿轮的旋转,触发光电开关,输出电信号。信号经过HEF40106BP整形后,生成标准的方波脉冲,输出至采集分站。
采集分站：实现对传感器信号的实时采集、存储、显示,并通过CAN总线与传输分站进行数据通信。采集分站支持PS／2键盘接口,可以通过PS／2键盘对采集分站进行参数设置。采集分站主板芯片采用PIC18F6585单片机,传感器信号采集及CAN通讯部分采用中断方式进行响应,对传感器信号采集优先处理,确保信号采集的实时性。
传输分站：实现与所有采集分站之间的数据通讯,对所有的采集分站进行巡检,现场显示各采集分站的当前数据,并通过单模光纤模块实现数据的远程传输。传输分站主板芯片也采用PIC18F6585单片机,通过对单片机I／O引脚的控制,实现液晶显示、I2C存储、CAN通讯、串口通讯等功能。
远程数据传输接口：传输接口核心采用MWF101-S单模光纤模块,光口通过单模光纤与井下传输分站的光纤模块连接,RS-232接口通过RS-232连接线与计算机RS-232接口连接。
上位机组态软件：上位机组态软件采用组态王6.52平台进行开发,主要包括人机界面、SQL Server数据库、WEB发布、OPC服务器等方面。良好的人机界面方便操作人员比较直观的观察数据,进行相关的数据分析以及报表打印等操作。SQL Server数据库用于保存在线接收的数据,供报表查询使用。WEB发布实现数据在局域网内的共享。OPC服务器使系统可以方便的与其他系统对接,实现数据共享。
系统优化设计：主要对系统的功耗和稳定性进行优化,从硬件的选型到系统运行中的一些降低功耗的设计,确保系统在电源功率一定的条件下,可以稳定的工作。通过设置软件陷阱、看门狗等方法,提高单片机程序运行的稳定性,防止程序跑飞。
本课题的创新点主要包括：一、根据光电开关的工作原理,将钢丝绳的机械位移转化成电脉冲信号,通过脉冲计数,反应出离层的实际值。二、通过CAN总线技术,实现对井下巷道顶板的长距离分布式实时监测。CAN总线技术的引入方便系统进行扩展,在电源功耗允许的条件下,系统可以根据巷道的长度自由组合。
China is the largest producer and consumer of coal in the world, the situation coal is our primary energy which will not change in the next 50 years. Coal mine safety has been an important factor of constraining development of coal industry for a long time. Roof problem is an important part of the coal mine safety problems. Monitoring the status of the roof, studying the law of the roof change, strengthening the roof in time, can ensure the roof safety effectively and reduce the security risk in production process. The main task of this dissertation is to design a Monitoring System on-line of roof separation that used in roadway underground. It's used in monitoring changes of roof timely, recording data of the roof changes, providing basic data analysis, and providing data basis for strengthening the roadway roof.
The main work of this dissertation includes displacement sensor design, collection substation design, transmission substation design, data transfer interface for long distance design, host computer congfiguration software design. Data is shared through web in local area network, and is docked with other system through OPC.
Displacement sensor:outputs electrical signal through photoelectric switch which is triggered by the high-accuracy gear wheel revolves. Signal is integered by HEF40106BP, and output standard square-wave pulse to collected substation.
Collectiont substation:achieves the signal collection real-time from sensor, storage, display, and data communication with transmitted substation by CAN bus. The collected substation supports PS/2 interface. Parameter of the collected substation can be set through PS/2 keyboard. The MCU of the collected substation's mainbaord is PIC18F6585, signal collection of sensor and CAN bus transmission are responsed by interruption. Priority processing of the sensor's signal can make sure the real-time of the signal's collection.
Transmission substation:achieves the data communication with all collected substations, loop checking for all collected substations, field showing the currunt data of every collected substation, and data communication for long distance by single mode fiber. The MCU of the transmitted substation's mainbaord is PIC18F6585 too. Trough the I/O pins'controlled of the MCU, to achieve LCD, I2C memory, CAN bus communication, serial communication and other functions.
Data transfer interface for long distance:the core is a MWF101-S SMF Module. It's connected with the SMF Module in transmitted substation underground by SMF, and connected with host computer by RS-232.
Host computer congfiguration software:it's developed based on Kingview 6.52. It includes man-machine interface, SQL Server Database, Web Publishing, OPC Server, etc. Good man-machine interface makes for operator to observe data intuitively, to do data analysisi, report printing and other operations. SQL Server Database is used for saving data that received on-line, and supplying for report query. Data is shared in LAN by Web Publishing and shared with other system by OPC Server.
System optimization design:it's mainly for system's power and stability. From hardware's selection to low power design in system's running, it makes sure the system running stably under a certain power range. Software trap and WDT can improve the stability of the program and prevent the program from losing control.
The main points of innovation of this dissertation includes:firstly, according to the principle of photoelectric switch, machinery displacement of steel wire rope is converted into electrical pulses. The count of the electrical pulses is the active value of separation. Secondly, achieving distributed monitoring of roadway roof underground for long distance through CAN bus. Because of the CAN bus is used, the system can be combined freely according to the length of roadway within the framework of the power.
引文
[1]宋振琪,蒋宇静,杨增夫等.煤矿重大事故预测和控制的动力信息基础的研究[M].北京：煤炭工业出版社,2003：89-90.
[2]文振明,张宏伟.顶板离层与监测[J].煤炭技术,2006,(03)：49-50.
[3]李冰冰,苏正江等.回采巷道顶板离层临界值分析[J].煤炭科技,2008,(01)：37-40.
[4]陈苏阳.顶板动态监测在陈四楼煤矿生产中的应用[J].中州煤炭,2007,(02)：5-6.
[5]李建辉,李日荣等.顶板监控系统在煤矿的运用[J].能源技术与管理,2007,(02)：86-87,110.
[6]位移传感器-光栅的原理和应用[DB／OL].http://www.gkcity.com/n-i-36341-c-Case.htm.
[7]毛灵涛,安千里等.光栅位移实时监测系统应用研究[J].煤炭科学技术,2007,(07)：100-102.
[8]张利霞,赵海燕,杨志成.光电式坐标传感器的设计[J].仪表技术与传感器,2007,(02)：4-5,35.
[9]PICmicro(?) 18C MCU系列参考手册[M].2005 Microchip Technology Inc.
[10]PIC18F6585/8585/6680/8680 Data Sheet.[M].2004 Microchip Technology Inc.
[11]LM3033B-0BR3 LCD Module User Manual[M]. Shenzhen TOPWAY Technology Co.,Ltd.
[12]ST7920中文字型点矩阵LCD控制／驱动器[M]
[13]著Adam Chapweske,译Roy Show. PS/2技术参考[M].
[14]成毅,庹先国,高嵩.PS／2键盘在51单片机系统中的应用[J].中国测试技术,2004,30(05)：60-62,76.
[15]CAN入门书[M].瑞萨科技,RCJ0580027-0100／Rev.1.00
[16]邵旻.CAN总线综述[M].2002.12.6
[17]PCA82C250 CAN收发器应用指南[M].广州周立功单片机发展有限公司
[18]Modbus通信协议[M]
[19]400/420／430／530控制器通信协议[M]
[20]冯向科,邓莹.基于MODBUS RTU通信协议下的CRC算法实现[J].电脑知识与技术,2006,(08)：43-43,59.
[21]程军,陈贵灿等.USB数据传输中CRC校验码的并行算法实现[J].微电子学与计算机,2003,(20-3)：77-80.
[22]高精度实时时钟-SD2300A(V1.20)[M]深圳市兴威帆电子技术有限公司.
[23]庄建清,徐玮.51单片机综合学习系统-DS1302时钟应用篇[J].电子制作,2008,(10)：25-26.
[24]256KI2CTM CMOS Serial EEPROM[M].2001 Microchip Technology Inc.
[25]CMOS串行EEPROM原理及应用[M].武汉力源电子股份有限公司,1993,3
[26]王出航,狄婧.I2C总线存储器的控制方法[J].长春师范学院学报,2008,(04)：31-32.
[27]刘增基,周洋溢等.光纤通信[M].西安：西安电子科技大学出版社,2001：4-8.
[28]项安,朱更军.256k位串行EEPROM24LC256原理及与DSP的接口应用[J].研发与应用,2004,(04)：4-6.
[29]邵思飞,宋永东,白宗文.24LC256在51单片机系统中的应用[J].延安大学学报,2004,(02)：39-42.
[30]MWF101-S RS-232单模光纤转换器[M].武汉迈威光电技术有限公司
[31]于宁,李文江等.应用组态软件实现计算机与单片机的串行通讯[J].仪器仪表用户,2005,(03)：90-91.
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[2]文振明,张宏伟.顶板离层与监测[J].煤炭技术,2006,(03)：49-50.
[3]李冰冰,苏正江等.回采巷道顶板离层临界值分析[J].煤炭科技,2008,(01)：37-40.
[4]陈苏阳.顶板动态监测在陈四楼煤矿生产中的应用[J].中州煤炭,2007,(02)：5-6.
[5]李建辉,李日荣等.顶板监控系统在煤矿的运用[J].能源技术与管理,2007,(02)：86-87,110.
[6]位移传感器-光栅的原理和应用[DB／OL].http://www.gkcity.com/n-i-36341-c-Case.htm.
[7]毛灵涛,安千里等.光栅位移实时监测系统应用研究[J].煤炭科学技术,2007,(07)：100-102.
[8]张利霞,赵海燕,杨志成.光电式坐标传感器的设计[J].仪表技术与传感器,2007,(02)：4-5,35.
[9]PICmicro(?) 18C MCU系列参考手册[M].2005 Microchip Technology Inc.
[10]PIC18F6585/8585/6680/8680 Data Sheet.[M].2004 Microchip Technology Inc.
[11]LM3033B-0BR3 LCD Module User Manual[M]. Shenzhen TOPWAY Technology Co.,Ltd.
[12]ST7920中文字型点矩阵LCD控制／驱动器[M]
[13]著Adam Chapweske,译Roy Show. PS/2技术参考[M].
[14]成毅,庹先国,高嵩.PS／2键盘在51单片机系统中的应用[J].中国测试技术,2004,30(05)：60-62,76.
[15]CAN入门书[M].瑞萨科技,RCJ0580027-0100／Rev.1.00
[16]邵旻.CAN总线综述[M].2002.12.6
[17]PCA82C250 CAN收发器应用指南[M].广州周立功单片机发展有限公司
[18]Modbus通信协议[M]
[19]400/420／430／530控制器通信协议[M]
[20]冯向科,邓莹.基于MODBUS RTU通信协议下的CRC算法实现[J].电脑知识与技术,2006,(08)：43-43,59.
[21]程军,陈贵灿等.USB数据传输中CRC校验码的并行算法实现[J].微电子学与计算机,2003,(20-3)：77-80.
[22]高精度实时时钟-SD2300A(V1.20)[M]深圳市兴威帆电子技术有限公司.
[23]庄建清,徐玮.51单片机综合学习系统-DS1302时钟应用篇[J].电子制作,2008,(10)：25-26.
[24]256KI2CTM CMOS Serial EEPROM[M].2001 Microchip Technology Inc.
[25]CMOS串行EEPROM原理及应用[M].武汉力源电子股份有限公司,1993,3
[26]王出航,狄婧.I2C总线存储器的控制方法[J].长春师范学院学报,2008,(04)：31-32.
[27]刘增基,周洋溢等.光纤通信[M].西安：西安电子科技大学出版社,2001：4-8.
[28]项安,朱更军.256k位串行EEPROM24LC256原理及与DSP的接口应用[J].研发与应用,2004,(04)：4-6.
[29]邵思飞,宋永东,白宗文.24LC256在51单片机系统中的应用[J].延安大学学报,2004,(02)：39-42.
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