WANG Y C WANG X W, MA K, et al. Research on the anti-collision monitoring and early warning system for hydraulic support panels and shearers based on omnidirectional laser radar[J]. Journal of Henan Polytechnic University(Natural Science) , 2025, 44(3): 44-52.

doi:10.16186/j.cnki.1673-9787.2024080051

Received:2024/08/29

Revised:2024/12/11

Online:2025-04-18

Research on the anti-collision monitoring and early warning system for hydraulic support panels and shearers based on omnidirectional laser radar

WANG Yichen1,2, WANG Xuewen1,2,3, MA Kai1,2, LI Hui1,2, NI Qiang4, XIE Jiacheng1,2,3

1.College of Mechanical Engineering， Taiyuan University of Technology， Taiyuan  030024， Shanxi， China；2.Shanxi Key Laboratory of Fully-Mechanized Coal Mining Equipment， Taiyuan University of Technology， Taiyuan  030024， Shanxi， China；3.National Key Laboratory of Intelligent Mining Equipment Technology， Taiyuan University of Technology， Taiyuan  030024， Shanxi， China；4.Shanxi Kangwei Group Co.， Ltd.， Changzhi  046006， Shanxi， China

Abstract: Objectives Collisions between the shearer roller and the face guard of the hydraulic support are prone to occur during the operation of the shearer. However， existing monitoring methods are hindered by the complexity of sensor data fusion， limited accuracy， and inherent lag，  which results in poor monitoring precision. Methods A spatial relative pose estimation method based on omnidirectional LiDAR was proposed to monitor collisions between the face guard of the hydraulic support and the shearer roller. The method comprises three main components： （1） A 3D laser scanning system， consisting of a 2D laser radar and a precision rotating platform， was installed beneath the hydraulic support beam to collect data from the target object. A pose estimation model for the face guard and the shearer roller was developed. （2） The SIFT algorithm was employed to extract feature points， allowing real-time analysis of the relative pose between the shearer roller and the face guard， and the creation of a behavior database. （3） A hierarchical warning mechanism was implemented. The Unity 3d visualization interface was used to display the status of the support plates， indicating whether they were abnormal， and to promptly issue alerts.  Results The relative pose information of 10 sets of hydraulic support face guards and shearer rollers was calculated in the laboratory to determine the potential for collisions. The results showed an average displacement error of 1.5 cm for the extension of the support plate， and an average tilt angle error of 1.7°. The relative errors were 4.5% for the x-axis， 3.6% for the y-axis， and 2.8% for the z-axis. Under five different working conditions， the mean absolute errors for the x， y and z axes were all less than 3.5 cm. The pose information effectively evaluated the cutting interference state， with results consistent with the actual situation， meeting the application requirements.  Conclusions The method enables the acquisition of the relative pose information of the face guard and shearer roller in three-dimensional space at relatively low cost， with high accuracy. Real-time collision monitoring improves the safety of underground equipment and the stability of the fully mechanized mining face.

Key words: shearer roller; face guard of hydraulic support; 2D laser radar; 3D scanning; anti-collision monitoring system