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WANG L, SUN K, YUAN R F,et al. Research on intelligent control system of hydraulic support based on EtherCAT[J]. Journal of Henan Polytechnic University(Natural Science) , 2025, 44(3): 53-63.

基于EtherCAT的液压支架智能控制系统研究

王磊1, 孙凯1, 袁瑞甫2, 齐俊艳3

1.河南理工大学 计算机科学与技术学院，河南 焦作  454000；2.河南理工大学 能源科学与工程学院，河南 焦作  454000；3.河南理工大学 软件学院，河南 焦作  454000

摘要: 目的 液压支架是煤矿开采的关键设备之一，为了解决液压支架通信网络通信速率低与同步性差的问题，  方法 以支撑掩护式液压支架为对象，设计一套完整的智能控制系统，深入探讨液压支架的数据传输与控制问题。EtherCAT通信基于标准的以太网数据帧，优化了协议栈的应用层和数据链路层。将EtherCAT总线应用于整个液压支架通信网络，完成液压支架智能控制系统的软硬件设计。将液压支架的单架控制、邻架控制和成组控制等命令结合EtherCAT报文嵌入以太网数据帧中，实现直达I/O的以太网控制。基于建立的液压支架运动模型，利用EtherCAT总线的高精度分布式时钟（DC）同步机制，实现对采煤机位姿及液压支架升降、推进、移动等动作的精确控制。  结果 采用EtherCAT总线替代传统的CAN总线后，通信速率从1 MB/s提升至100 MB/s，显著增强了数据传输的速度和效率。同时，网络拓扑结构从单一的总线型扩展为更加灵活的混合拓扑结构，适应范围更广。主站对液压支架的统一管理和控制，有效简化了网络管理的复杂性。利用EtherCAT的分布时钟（DC）同步机制，实现了微秒级的运动控制更新周期，确保了液压支架从站与主站之间的快速数据交换。  结论 通过引入EtherCAT总线技术，显著提升了液压支架的控制效率和通信速率。研究结果不仅完善了智能无人采煤开采技术体系，为后续研究及现场应用提供了重要参考，还对促进煤矿工作面的安全高效生产具有重要意义。

关键词:液压支架;EtherCAT;监控分站;煤矿开采;故障报警

doi:10.16186/j.cnki.1673-9787.2024110014

基金项目:国家自然科学基金资助项目（52204168）；河南省高校科技创新团队支持计划项目（22IRTSTHN005）

收稿日期:2024/11/07

修回日期:2025/01/15

出版日期:2025-04-18

Research on intelligent control system of hydraulic support based on EtherCAT

WANG Lei1, SUN Kai1, YUAN Ruifu2, QI Junyan3

1.School of Computer Science and Technology， Henan Polytechnic University， Jiaozuo  454000， Henan， China；2.School of Energy Science and Engineering， Henan Polytechnic University， Jiaozuo  454000， Henan， China；3.School of Software， Henan Polytechnic University， Jiaozuo  454000， Henan， China

Abstract: Objectives Hydraulic support is one of the key equipments in coal mining. In order to solve the problem of low communication rate and poor synchronization of hydraulic support communication network，  Methods a complete intelligent control system was designed for supporting and covering hydraulic support，and the data transmission and control of the hydraulic support were discussed in depth. EtherCAT communication was based on standard Ethernet data frames and was optimized in the application layer and data link layer of the protocol stack. The EtherCAT bus was applied to the whole hydraulic support communication network to complete the hardware and software design of the hydraulic support intelligent control system. The commands for single-frame control， neighboring-frame control and group control of hydraulic supports were embedded in Ethernet data frames with EtherCAT telegrams to realize the Ethernet control of direct I/O. Based on the established hydraulic support motion model， the high-precision distributed clock（DC） synchronization mechanism of the EtherCAT bus was utilized to realize the precise control of the position of the coal miner and the movements of the hydraulic support such as lifting， advancing and moving.  Results By replacing the conventional CAN bus with the EtherCAT bus， the communication rate was increased from 1 Mbps to 100 Mbps， which significantly enhanced the speed and efficiency of data transmission. At the same time， the network topology was expanded from a single bus type to a more flexible hybrid topology with a wider range of adaptability. The unified management and control of hydraulic support by the master station effectively simplified the complexity of network management. By utilizing EtherCAT Distributed Clock （DC） synchronization mechanism， a microsecond motion control update cycle was achieved， which ensured fast data exchange between the hydraulic support slaves and the master. Conclusions By introducing the EtherCAT bus technology， the control efficiency and communication rate of the hydraulic support were significantly improved. The results of this study not only improved the intelligent unmanned coal mining technology system，but also provided an important reference for subsequent research and field application， and was also of great significance in promoting the safe and efficient production of coal mine working face.

Key words: hydraulic support; EtherCAT; monitoring substation; coal mining; fault alarm