To further enhance the intelligence level of coal mining faces and achieve the autonomous derivation, learning, and optimization of shearer navigation cutting, this paper proposes the methods of shearer digital twin navigation cutting motion planning based on the concept of shearer autonomous navigation cutting technology and intelligent coal mining face digital twins. This study includes the digital twin theory and the construction method of the shearer digital twin navigation cutting motion planning system based on this theory. Based on the digital twin theory, a shearer digital twin navigation cutting motion planning system was constructed. This system supports the service functions of the shearer cutting digital twin, dynamic navigation map digital twin, reinforcement learning environment construction, and motion planning through the physical perception layer, comprehensive data layer, and digital–model fusion analysis layer. Finally, by comparing the effects of the DQN-NAF and DDPG deep reinforcement learning algorithms in the shearer motion planning task within the constructed digital twin environment, the results show that the DQN-NAF algorithm demonstrates better performance and stability in solving the shearer digital twin motion planning task.

The shearer is an important component of the smart mining workface, and its effective control is a key aspect that guarantees safe and high-efficient production in coal mines. To address the issue of autonomous height adjustment during the shearer’s cutting process, a self-adaptive speed control method driven by digital twin technology is proposed. A digital twin-based control architecture for the shearer is first established, which consists of physical and the corresponding virtual entities, as well as reality–virtual interaction between them. Based on the mathematic model formulated for height adjustment system of the shearer, an adaptive fuzzy sliding mode controller (AFSMC) with the displacement estimation is designed for the virtual entity, with the purpose of guiding the operation of the corresponding physical entity. Simulation experiments on MATLAB compares the control performance among the proposed method and four comparative ones, including PID controller, integral sliding mode controller (ISMC), feedback linearization controller (FLC), and fuzzy sliding mode controller (FSMC). The experimental results confirm the effectiveness of the proposed AFSMC. More specifically, its steady-state error is 0.024, the maximum absolute control input is 8.43, and the settling time is 1.74 s. This also proves that the digital twin-based control method enables the precise adaptive height adjustment of the shearer, providing potential reference for the intelligent development of a smart mining workface.

The main focus of this work is the design and development of a three-dimensional force sensor for the cutting pick of a coal mining shearer’s simulated drum. This sensor is capable of simultaneously measuring the magnitude of force along three directions of the cutting pick during the cutting sample process. The three-dimensional force sensor is built based on the strain theory of material mechanics, and reasonable structural design is implemented to improve its sensitivity and reduce inter-axis coupling errors. The strain distribution of the sensor is analyzed using finite element analysis software, and the distribution of the strain gauges is determined based on the analysis results. In addition, a calibration test system is designed for the sensor, and the sensitivity, linearity, and inter-axis coupling errors of the sensor are calibrated and tested using loading experiments in three mutually perpendicular directions. Modal simulation analysis and actual cutting pick testing of the coal mining machine’s simulated drum are conducted to study the dynamic characteristics and functionality of the sensor in practical applications. The experimental results depict sensitivities of 0.748 mV/V, 2.367 mV/V, and 2.83 mV/V for the newly developed sensor, respectively. Furthermore, the cross-sensitivity error was lower than 5.02%. These findings validate that the sensor’s structure satisfies the measurement requirements for pick-cutting forces.

To further enhance the intelligence level of coal mining faces and achieve autonomous derivation, learning, and optimization of shearer navigation cutting, this paper proposes the methods of shearer digital twin navigation cutting motion planning based on the concept of shearer autonomous navigation cutting technology and intelligent coal mining face digital twins. The study includes the digital twin theory and the construction method of the shearer digital twin navigation cutting motion planning system based on this theory. Based on the digital twin theory, a shearer digital twin navigation cutting motion planning system was constructed. This system supports the service functions of shearer cutting digital twin, dynamic navigation map digital twin, reinforcement learning environment construction, and motion planning through the physical perception layer, comprehensive data layer, and digital-model fusion analysis layer. Finally, by comparing the effects of the DQN-NAF and DDPG deep reinforcement learning algorithms in the shearer motion planning task within the constructed digital twin environment, the results show that the DQN-NAF algorithm demonstrates better performance and stability in solving the shearer digital twin motion planning task.

In auxiliary transportation within mines, accurately assessing the cognitive and response states of drivers is vital for ensuring safety and operational efficiency. This study investigates the effects of various vehicle interaction stimuli on the electroencephalography (EEG) signals of mine transport vehicle drivers, analyzing the cognitive and response states of drivers under different conditions to evaluate their impact on safety performance. Through experimental design, we simulate multiple scenarios encountered in real operations, including interactions with dynamic and static vehicles, personnel, and warning signs. EEG technology records brain signals during these scenarios, and data analysis reveals changes in the cognitive states and responses of drivers to different stimuli. The results indicate significant variations in EEG signals with interactions involving dynamic and static vehicles, personnel, and warning signs, reflecting shifts in the cognitive and response states of drivers. Additionally, the study examines the overall impact of different interaction objects and environments. The detailed analysis of EEG signals in different scenarios sheds light on changes in perception, attention, and responses related to drivers, which is critical for advancing safety and sustainability in mining operations.

This study presents an advanced simulated shearer machine cutting experiment system enhanced with digital twin technology. Central to this system is a simulated shearer drum, designed based on similarity theory to accurately mirror the operational dynamics of actual mining cutters. The setup incorporates a modified machining center equipped with sophisticated sensors that monitor various parameters such as cutting states, forces, torque, vibration, temperature, and sound. These sensors are crucial for precisely simulating the shearer cutting actions. The integration of digital twin technology is pivotal, featuring a real-time data management layer, a dynamic simulation mechanism model layer, and an application service layer that facilitates virtual experiments and algorithm refinement. This multifaceted approach allows for in-depth analysis of simulated coal cutting, utilizing sensor data to comprehensively evaluate the shearer’s performance. The study also includes tests on simulated coal samples. The system effectively conducts experiments and captures cutting condition signals via the sensors. Through time domain analysis of these signals, gathered while cutting materials of varying strengths, it is determined that the cutting force signal characteristics are particularly distinct. By isolating the cutting force signal as a key feature, the system can effectively distinguish between different cutting modes. This capability provides a robust experimental basis for coal rock identification research, offering significant insights into the nuances of shearer operation.