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Article(id=1149754265633211205, tenantId=1146029695717560320, journalId=1146031787341344770, issueId=1149754257689194795, articleNumber=1003-3033(2024)S1-0134-06, orderNo=null, doi=10.16265/j.cnki.issn1003-3033.2024.S1.0039, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1710345600000, receivedDateStr=2024-03-14, revisedDate=1715875200000, revisedDateStr=2024-05-17, acceptedDate=null, acceptedDateStr=null, onlineDate=1752052378327, onlineDateStr=2025-07-09, pubDate=1719676800000, pubDateStr=2024-06-30, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1752052378327, onlineIssueDateStr=2025-07-09, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1752052378327, creator=13701087609, updateTime=1752052378327, updator=13701087609, issue=Issue{id=1149754257689194795, tenantId=1146029695717560320, journalId=1146031787341344770, year='2024', volume='34', issue='S1', pageStart='1', pageEnd='284', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=0, createTime=1752052376434, creator=13701087609, updateTime=1756362003807, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1167830145076311009, tenantId=1146029695717560320, journalId=1146031787341344770, issueId=1149754257689194795, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1167830145076311010, tenantId=1146029695717560320, journalId=1146031787341344770, issueId=1149754257689194795, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=134, endPage=139, ext={EN=ArticleExt(id=1149754265855509318, articleId=1149754265633211205, tenantId=1146029695717560320, journalId=1146031787341344770, language=EN, title=Research on safety condition monitoring technology of drilling rigs based on digital twins, columnId=1149733269173878863, journalTitle=China Safety Science Journal, columnName=Safety engineering technology, runingTitle=null, highlight=null, articleAbstract=

In order to prevent safety accidents caused by fatigue failure of mining drilling rigs due to overload，a safety condition monitoring technology of drilling rigs based on digital twins was studied. First，the overall framework of the digital twins-based monitoring system for safe operation conditions of drilling rigs was proposed，and then a real-time analysis method of drilling rig stress conditions based on a proxy model was studied. The finite element method was used to obtain stress distribution and amplitude data sets of the rig overturning frame，which were used for training and testing the proxy model. The results show that the maximum difference between the large-scale stress value calculated by the finite element method and the predicted value by the proxy model does not exceed 5×10-6 MPa. The absolute variance of the difference between the predicted values and the calculated values at all nodes is about 2×10-6 MPa. This shows that the proposed proxy model can be used instead of the finite element method to analyze the real-time stress of the rig overturning frame.

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为预防矿用钻机因过载产生疲劳失效而诱发安全事故，提出基于数字孪生的钻机运行安全状态监测技术。首先，提出钻机运行安全状态数字孪生监控系统整体框架；然后，提出基于代理模型的钻机受力状态实时分析方法；最后，利用有限元法获取钻机翻转框架应力分布及幅值数据集，用于对代理模型的训练和测试。结果表明：有限元计算的做大应力值与代理模型预测值之间的差值最大不超过5×10-6 MPa。且所有节点预测值与计算值之差的绝对值方差约为2×10-6 MPa。这表明所提出的代理模型可用于代替有限元方法实时分析钻机翻转框架的应力。

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王 晗 (1979—)，男，山东诸城人，本科，工程师，主要从事煤炭开采与机电设备管理方面的工作。E-mail：。

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王 晗 (1979—)，男，山东诸城人，本科，工程师，主要从事煤炭开采与机电设备管理方面的工作。E-mail：。

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王 晗 (1979—)，男，山东诸城人，本科，工程师，主要从事煤炭开采与机电设备管理方面的工作。E-mail：。

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Journal of system Simulation, 2024, 36(2):463-475., articleTitle=Design of 3D visual monitoring system for oil field pumping unit based on Unity3D, refAbstract=null)], funds=null, companyList=[AuthorCompany(id=1167751339007287771, tenantId=1146029695717560320, journalId=1146031787341344770, articleId=1149754265633211205, xref=null, ext=[AuthorCompanyExt(id=1167751339015676380, tenantId=1146029695717560320, journalId=1146031787341344770, articleId=1149754265633211205, companyId=1167751339007287771, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=Open-pit Coal Mine of Baori Shiller Energy Co.，Ltd.，National Energy Group，Hulun Buir Inner Mongolia 021008，China), AuthorCompanyExt(id=1167751339024064989, tenantId=1146029695717560320, journalId=1146031787341344770, articleId=1149754265633211205, companyId=1167751339007287771, language=CN, country=null, province=null, city=null, postcode=null, companyName=null, 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tableContent=null), ArticleFig(id=1167751341251240450, tenantId=1146029695717560320, journalId=1146031787341344770, articleId=1149754265633211205, language=CN, label=图7, caption=钻进过程数字孪生可视化, figureFileSmall=0YuKcoO1r3Aiyim2NZ/bgg==, figureFileBig=n9IfVKmaCeAQMhNnLST1Vw==, tableContent=null), ArticleFig(id=1167751341326737923, tenantId=1146029695717560320, journalId=1146031787341344770, articleId=1149754265633211205, language=EN, label=Table 1, caption=

Material performance parameters

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材料 密度ρ/
(kg·m-3)		 弹性模量
E/MPa		 泊松比
μ		 屈服强度
Rel/MPa		 抗拉强度
Rm/MPa
Q345B 7 850 2.06×105 0.28 345 470
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材料性能参数

, figureFileSmall=null, figureFileBig=null, tableContent=
材料 密度ρ/
(kg·m-3)		 弹性模量
E/MPa		 泊松比
μ		 屈服强度
Rel/MPa		 抗拉强度
Rm/MPa
Q345B 7 850 2.06×105 0.28 345 470
), ArticleFig(id=1167751341473538565, tenantId=1146029695717560320, journalId=1146031787341344770, articleId=1149754265633211205, language=EN, label=Table 2, caption=

Stress amplitude and calculation time of overturning frame with different mesh numbers

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整体网格数量 应力幅值/MPa 计算时间/s
3 230 82.35 21
8 545 80.42 42
13 873 83.25 49
15 943 81.40 75
32 096 81.62 117
55 296 80.95 135
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不同网格数量的翻转框架应力幅值及计算时间

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整体网格数量 应力幅值/MPa 计算时间/s
3 230 82.35 21
8 545 80.42 42
13 873 83.25 49
15 943 81.40 75
32 096 81.62 117
55 296 80.95 135
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基于数字孪生的钻机运行安全状态监测技术研究
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王晗
中国安全科学学报 | 安全工程技术 2024,34(S1): 134-139
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中国安全科学学报 | 安全工程技术 2024, 34(S1): 134-139
基于数字孪生的钻机运行安全状态监测技术研究
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王晗
作者信息
  • 国家能源集团宝日希勒能源有限公司 露天煤矿，内蒙古 呼伦贝尔 021008

    • 王 晗 (1979—)，男，山东诸城人，本科，工程师，主要从事煤炭开采与机电设备管理方面的工作。E-mail：。

Research on safety condition monitoring technology of drilling rigs based on digital twins
Han WANG
Affiliations
  • Open-pit Coal Mine of Baori Shiller Energy Co.，Ltd.，National Energy Group，Hulun Buir Inner Mongolia 021008，China
出版时间: 2024-06-30 doi: 10.16265/j.cnki.issn1003-3033.2024.S1.0039
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摘要
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为预防矿用钻机因过载产生疲劳失效而诱发安全事故，提出基于数字孪生的钻机运行安全状态监测技术。首先，提出钻机运行安全状态数字孪生监控系统整体框架；然后，提出基于代理模型的钻机受力状态实时分析方法；最后，利用有限元法获取钻机翻转框架应力分布及幅值数据集，用于对代理模型的训练和测试。结果表明：有限元计算的做大应力值与代理模型预测值之间的差值最大不超过5×10-6 MPa。且所有节点预测值与计算值之差的绝对值方差约为2×10-6 MPa。这表明所提出的代理模型可用于代替有限元方法实时分析钻机翻转框架的应力。

数字孪生  /  矿用钻机  /  状态监测  /  代理模型  /  受力状态

In order to prevent safety accidents caused by fatigue failure of mining drilling rigs due to overload，a safety condition monitoring technology of drilling rigs based on digital twins was studied. First，the overall framework of the digital twins-based monitoring system for safe operation conditions of drilling rigs was proposed，and then a real-time analysis method of drilling rig stress conditions based on a proxy model was studied. The finite element method was used to obtain stress distribution and amplitude data sets of the rig overturning frame，which were used for training and testing the proxy model. The results show that the maximum difference between the large-scale stress value calculated by the finite element method and the predicted value by the proxy model does not exceed 5×10-6 MPa. The absolute variance of the difference between the predicted values and the calculated values at all nodes is about 2×10-6 MPa. This shows that the proposed proxy model can be used instead of the finite element method to analyze the real-time stress of the rig overturning frame.

digital twins  /  mining drilling rig  /  condition monitoring  /  proxy model  /  stress condition
王晗. 基于数字孪生的钻机运行安全状态监测技术研究. 中国安全科学学报, 2024 , 34 (S1) : 134 -139 . DOI: 10.16265/j.cnki.issn1003-3033.2024.S1.0039
Han WANG. Research on safety condition monitoring technology of drilling rigs based on digital twins[J]. China Safety Science Journal, 2024 , 34 (S1) : 134 -139 . DOI: 10.16265/j.cnki.issn1003-3033.2024.S1.0039
正文
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0 引言
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钻孔作业是煤矿开采不可缺少的环节[1-2]，钻机是煤矿广泛使用的设备。钻进过程中煤岩属性复杂多变、钻进事故频发等问题影响矿用钻机安全高效使用。
近年来，越来越多的专家学者将数字孪生技术应用于矿用重大设备的安全运行监测中。如DONG等[3]分析当前采掘工作面工况，指出采掘工作面中存在的不足与挑战，并提出以数字孪生驱动智慧矿山发展的整体框架。在矿山设备维护与智能控制方面，张旭辉等[4-5]在软件Unity中搭建基于数字孪生技术的复杂矿用设备预测性维护系统，并以采煤机为研究对象进行试验验证；王岩[6]、杨文娟[7]等分别从工作面的智能控制、设备的智能定位、设备间的碰撞检测方法、数字孪生驱动的掘进机器人控制系统、掘进机器人截割控制方法等多个角度展开了研究，并取得了显著的成果；TEMKIN等[8]提出一种矿山数字孪生平台建模方法，并通过虚拟引擎搭建了露天矿监控预测平台。尽管国内外众多学者致力于研究大型装备的数字孪生技术，大多数研究仍仅局限于在几何层面上复现机械的动作和位置信息，而对机械在实时应力分析方面的研究较少。
鉴于此，笔者拟提出一种基于数字孪生方法的钻机高效运行安全状态监测方法，通过虚拟孪生模型指导物理设备完成预定目标。利用通用3D引擎软件搭建基于数字孪生的智能钻进仿真模拟系统，以期有效提高对钻机设备健康状态监测的准确性，降低设备发生故障的可能性。
1 钻机运行安全状态数字孪生监控
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煤矿装备工况环境恶劣，直接导致矿用钻机设备作业工况复杂多变。在这种条件下，矿用钻机设备健康状态监测过程中数据的利用率较低，难以依靠人工经验和传统监测方法(感官检验与诊断技术、温度检测技术、电气与液压诊断技术等)监测其施工状态。因此，设计一种基于代理模型的钻机关键零部件健康监测系统。
根据矿用钻机设备钻孔作业基本内容以及试验作业环境，设计监控系统构架。物理实体主要包括钻机设备、可编程逻辑控制器设备、核心部件传感器、视频监控设备等[9]。同时，由于矿用钻机设备作业环境缺乏网络信号覆盖，因此，采用有线局域网来模拟信息传输。为保证虚拟设备的准确性，需要采集矿用钻机设备运行过程中数据，采集完成后还需要处理数据。服务层主要为用户提供以下服务：状态显示，关键部件实时应力云图变化，并通过分析处理受力状态、疲劳损伤状态等，预测健康数据，实现故障预警[12]。系统架构和运行流程如图1所示。
2 钻机受力状态实时孪生分析
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2.1 代理模型构建
对于大型机械设备，其体积巨大且运行过程中受力状态复杂多变。这使得设备的应变或应力难以准确测量，而设备的具体应力分布则是其安全运行的重要性能指标[10]。在工程领域，虽然常运用多体动力学、有限元分析等数值模拟方法进行大型结构的力学状态分析，但对于大规模复杂的系统，这些方法的计算量大，需要大量硬件资源，且计算时间长，这几种方法无法确保数字孪生技术中提及的时效性要求。因此，对于需要多维设计变量且计算量庞大的大型机械，引入力学性能的快速分析技术。这些技术的核心在于保证计算精度的前提下降低计算量。
代理模型通常是指在优化设计中可替代比较复杂和费时的数值分析的近似数学模型，也可称为响应面模型或近似模型[11]。这是基于一组或多组已知的样本点及样本点对应的响应值找到一个关系式，使得样本点与响应值一一对应[15]。样本点与响应值的关系式如下：
y = f ( x ) + ε
式中：x为已知样本点，x∈{x1，x2，…，xk};y为样本点对应的响应值，y∈{y1，y2，…，yk};f(x)为近似函数关系式；ε为近似函数值与响应值之间的差值，一般情况下，ε值越小代表着近似函数保真度越高。
代理模型建立分为方案设计阶段、精度验证阶段和模型运用阶段3个阶段。其中，方案设计阶段主要包括模型训练样本的收集以及代理模型形式的选择。代理模型训练数据的获取方式有多种，包括有限元仿真结果处理、截割试验和传感器采集等。在收集到代理模型数据后仍需要对训练样本进行试验方案设计。当确定好训练集后即可选用不同的代理模型形式进行代理模型训练，每得到1组训练结果便可验证模型精度。若所训练的模型不满足精度要求，这需要重新调整所选用代理模型的基函数、均值、方差、权重等，必要时可换用其他形式的代理模型以获得更高的拟合精度。除此之外，也可重新设计训练样本集方案，选取覆盖面更广、分布更均匀的训练数据。循环往复，直到代理模型能够达到精度使用要求。详细的代理模型建立流程如图2所示。
综合考虑矿用钻机翻转框架的结构特点及有限元网格特点，以K近邻(K-Nearest Neighbors，KNN)归类算法为基础获取采样域，并利用拉丁立方采样方式在采样域中抽样，并将所获取的样本点用于求解粗糙网格节点的属性值，实现对有限元网格的预处理。将所求得的属性值作为代理模型训练的样本数据，对有限元网格的每一个节点建立代理模型。在进行代理模型训练时，将所收集的样本点分为2个部分，以2/3的数据为训练样本，另外的1/3为验证样本，通过不断调整代理模型的类型、同一模型的基函数、均值、方差、权重等参数，使验证样本尽可能的贴近训练样本所拟合的代理模型曲线，直至找到1条满足使用要求的代理模型。
2.2 数据集准备
建立代理模型整体框架后，使用矿用钻机翻转框架的受力数据训练和测试代理模型。使用有限元方法受力分析钻机翻转框架，得到200组数据，其中，140组用于训练模型，60组用于测试模型。
翻转框架主要是支撑钻机在工作时所受的轴向力，经计算所得。在机器平稳运行时，翻转框架端面所受最大载荷为20 MPa，另一端面固定，受力状态如图3所示。
翻转框架尺寸为2.5 m×0.3 m×0.3 m，质量为450 kg，材料为Q345B结构钢，该钢材的机械性能指标见表1。
为满足使用要求，翻转框架的实际结构较为复杂，其中，包含各铰接孔、螺纹孔、各尺寸倒角及加工后的法兰等。其微小结构对优化并无影响，因此，在三维建模时会忽略这些结构，只考虑翻转框架主体结构及减重槽结构设计。通过ANSYS软件中的Workbench模块，整体采用四面体网格进行有限元分析。FERZIGER等[12-13]通过理论分析后得出结论，即网格质量与有限元分析结果误差呈现正反馈关系，即提高模型的网格质量，会有效降低最终的有限元分析结果和模型实际应用下的结果误差。因此，为保证各网格质量，以及仿真计算的正确性，需要无关性检查网格。
网格数量在15 943~22 096和22 096~55 296范围内时，得到的有限元分析结果中的应力幅值的变化相对于其他网格数量来说，其变化幅度较小，说明其结果与真实结果的误差也较小。应力幅值及计算时间随网格数量变化的趋势如图4所示。从图4可以看出，当网格达到15 943及以上时，有限元分析出的应力结果变化逐渐稳定下来，得到的结果真实性大大提高。所以在确保仿真结果真实性的同时，也要使计算效率尽可能高，最后决定将模型的网格数量定为15 943。不同网格数量的翻转框架应力幅值结果及计算时间见表2。
在有限元分析之前，验证模型中的网格，以确保所使用的网格对分析结果没有或只有较小的影响，并选择最佳的网格划分方案，使用4面体单元将翻转框架的结构离散化，最终在该有限元模型中，共包含15 943个单元，这些单元是相互连接并组成整个结构的小单元。同时，模型中还有33 794个节点，这些节点代表结构中的各个连接点或关键位置，用于描述节点的坐标和位移等信息。
通过有限元分析等方法，分析翻转框架在正常使用和荷载下，各个部位的应力分布情况。由于简化三维模型之后，翻转框架端面的外围部分受钻机给的均匀载荷，在钻机工作时，载荷有一个起伏波动，经过试验分析后，决定取其正常工作情况下的最大载荷，为20 MPa，固定约束翻转框架，最后对其进行有限元计算分析。根据仿真结果分析，发现翻转框架的矩形镂空界面的边缘处，应力的变化幅度最大，此时翻转框架结构内应力分布情况如图5所示。由图5可知：在该结构中所受到的应力变化的最大幅值为82.4 MPa，并且主要的应力集中区域位于矩形镂空的区域以及镂空的4边周围。在避免结构的强度和稳定性受到影响前提下，优化和改进原有的结构空洞或镂空部分，实现减轻结构重量的目标，保持该结构的应力水平不变。
2.3 实时应力分析
收集并处理代理模型训练样本后，使用其余60组数据测试代理模型，得到代理模型对不同工况下钻机翻转框架实时受力分析结果和有限结果计算得到的应力分析结果对比，如图6所示。
有限元计算的做大应力值与代理模型预测值之间的差值最大不超过5×10-6 MPa。且所有节点预测值与计算值之差的绝对值方差均很小，约为2×10-6。这表明：提出的代理模型建立方法所拟合的代理模型曲线在样本点附近具有较高的拟合度，代理模型可代替有限元计算用于对钻机翻转框架展开实时应力分析。
3 基于数字孪生的运行安全状态监测
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使用 SolidWorks 软件进行钻机设备的建模，再使用 Cinema4D 进行钻机设备的可视化建模仿真[14]。考虑工况环境、设备构成、工艺流程等因素，构建钻进设备虚拟数字孪生模型，实现钻孔的三维可视化展示，并通过数据驱动实现煤层钻进和虚拟煤层钻进的实时对应，具体包括钻孔轨迹信息、钻杆三维成孔信息、钻进速度分析、工作人员数量监测及钻孔质量监测等的模拟仿真服务平台，如图7所示。该服务平台的构建将会为复杂地质条件下钻进设备的自适应控制与人机交互功能提供技术基础。
实时读取压缩机、液压系统、电控系统等钻机各部分设备的故障信息，并反馈给钻机自动运行控制系统，由系统进行故障诊断和识别，将分析结果反馈给控制中心做出进一步处理结果[15]。
读取的数据信息包括：①压缩机、液压系统、电控系统故障信息；②全球定位系统等定位通信设备信息；③高性能传感器采集的振动频率信息；④视频图像处理信息；⑤钻机受力状态实时分析结果。
将车载视频安装在钻机周围和驾驶室内部，用于监控钻机的作业环境。钻机周围使用附带强光抑制功能的红外枪型摄像机，驾驶室内安装高速球型摄像机。
视频信号一路进行图像处理，为作业平盘安全检测、钻机运行时的电缆管理提供有效信息，避免发生事故。
4 结论
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1) 提出一种基于代理模型的钻机关键零部件健康监测系统，能够有效提高对钻机设备健康状态监测的准确性，降低设备发生故障的可能性。
2) 代理模型建立方法所拟合的代理模型曲线在样本点附近具有较高的拟合度，所建立的代理模型可代替有限元计算用于对钻机翻转框架展开实时应力的分析。
3) 目前主要采用有限元数据训练代理模型，在未来研究中将会使用实测数据实时驱动钻机运行状态分析模型，从而得到更加真实的钻机实时受力状态。
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2024年第34卷第S1期
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doi: 10.16265/j.cnki.issn1003-3033.2024.S1.0039
  • 接收时间：2024-03-14
  • 首发时间：2025-07-09
  • 出版时间：2024-06-30
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  • 收稿日期：2024-03-14
  • 修回日期：2024-05-17
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    国家能源集团宝日希勒能源有限公司 露天煤矿，内蒙古 呼伦贝尔 021008
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2种不同金属材料的力学参数
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Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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