In order to improve the performance of the hydraulic support electro-hydraulic control system test platform, a self-tuning proportion integration differentiation (PID) controller is proposed to imitate the actual pressure of the hydraulic support. To avoid the premature convergence and to improve the convergence velocity for tuning PID parameters, the PID controller is optimized with a hybrid optimization algorithm integrated with the particle swarm algorithm (PSO) and genetic algorithm (GA). A selection probability and an adaptive cross probability are introduced into the PSO to enhance the diversity of particles. The proportional overflow valve is installed to control the pressure of the pillar cylinder. The data of the control voltage of the proportional relief valve amplifier and pillar pressure are collected to acquire the system transfer function. Several simulations with different methods are performed on the hydraulic cylinder pressure system. The results demonstrate that the hybrid algorithm for a PID controller has comparatively better global search ability and faster convergence velocity on the pressure control of the hydraulic cylinder. Finally, an experiment is conducted to verify the validity of the proposed method.

Generally, the sound signal produced by transmission unit or cutting unit contains abundant information about the working state of a machine. The acoustic-based diagnosis system presents some distinct advantages in some severe conditions particularly due to its unique non-contact measurement and unlimited use at the installation site. However, the original acoustic signal collected from manufacture process is always polluted by various background noises. In order to eliminate noise components from machinery sound effectively, an empirical mode decomposition (EMD) threshold denoising method optimized by an improved fruit fly optimization algorithm (IFOA) is launched in this paper. The acoustic signal was first decomposed by the adaptive EMD to obtain a series of intrinsic mode functions (IMFs). Then, the soft threshold function was applied to shrink the IMF coefficients. While the threshold of each IMF was determined by statistical estimation and empirical value for traditional EMD denoising, the denoising effect was often not desired and time-consuming. To solve these disadvantages, fruit fly optimization algorithm (FOA) was introduced to search global optimal threshold of each IMF. Moreover, to enhance the group diversity during production of the next generation of fruit flies and balance the local and global searching ability, a variation coefficient and a disturbance coefficient was introduced to the basic FOA. Then, a piece of simulated acoustic signal produced by the train was applied to validate the proposed EMD and IFOA threshold denoising (EMD-IFOA). The simulation results, which decreased 35.40% and 18.92% in mean squared error (MSE) and percent root mean square difference (PRD) respectively, and increased 40.36% in signal-to-noise ratio improvement (SNR_imp) compared with basic EMD denoising scheme at SNR = 5 dB, illustrated the effectiveness and superiority of the proposed approach. Finally, the proposed EMD-IFOA was conducted on an actual acoustic-based diagnosis system for cutting state recognition of the coal mining shearer to demonstrate the practical effect.

As a sound signal has the advantages of non-contacted measurement, compact structure, and low power consumption, it has resulted in much attention in many fields. In this paper, the sound signal of the coal mining shearer is analyzed to realize the accurate online cutting pattern identification and guarantee the safety quality of the working face. The original acoustic signal is first collected through an industrial microphone and decomposed by adaptive ensemble empirical mode decomposition (EEMD). A 13-dimensional set composed by the normalized energy of each level is extracted as the feature vector in the next step. Then, a swarm intelligence optimization algorithm inspired by bat foraging behavior is applied to determine key parameters of the traditional variable translation wavelet neural network (VTWNN). Moreover, a disturbance coefficient is introduced into the basic bat algorithm (BA) to overcome the disadvantage of easily falling into local extremum and limited exploration ability. The VTWNN optimized by the modified BA (VTWNN-MBA) is used as the cutting pattern recognizer. Finally, a simulation example, with an accuracy of 95.25%, and a series of comparisons are conducted to prove the effectiveness and superiority of the proposed method.

As the conventional cutting pattern recognition methods for shearer are huge in size, have low recognition reliability and an inconvenient contacting measurement method, a fast and reliable coal-rock cutting pattern recognition system is always a baffling problem worldwide. However, the recognition rate has a direct relation with the outputs of coal mining and the safety quality of staff. In this paper, a novel cutting pattern identification method through the cutting acoustic signal of the shearer is proposed. The signal is clustering by fuzzy C-means (FCM) and a hybrid optimization algorithm, combining the fruit fly and genetic optimization algorithm (FGOA). Firstly, an industrial microphone is installed on the shearer and the acoustic signal is collected as the source signal due to its obvious advantages of compact size, non-contact measurement and ease of remote transmission. The original sound is decomposed by multi-resolution wavelet packet transform (WPT), and the normalized energy of each node is extracted as a feature vector. Then, FGOA, by introducing a genetic proportion coefficient into the basic fruit fly optimization algorithm (FOA), is applied to overcome the disadvantages of being time-consuming and sensitivity to initial centroids of the traditional FCM. A simulation example, with the accuracy of 95%, and some comparisons prove the effectiveness and superiority of the proposed scheme. Finally, an industrial test validates the practical effect.

The horizontal bending angle of scraper conveyor has a great influence on the running resistance, the current consumption, coal winning efficiency of the working surface, etc. Approximately 1–3° is usually the range of horizontal bending angle, but does not indicate the optimum bending angle of the coal mining face. To find the optimal horizontal bending angle, an optimization method is proposed. A mathematical calculation model of the running resistance of the scraper is established based on the direction of the shearer operation. Then, a method of adjusting the step size of the search by inertia weight and expanding fly distance range obeying the t-distribution is proposed based on the basic bat algorithm (BA). Finally, an industrial application was conducted in 21220 Changcun fully mechanized coal mining face, Henan Province. The results show that the current consumption by the scraper conveyor was reduced by 31% when the horizontal bending angle of the S-bending area was 0.66°. Meanwhile, the theoretical current has good consistency with the experimental data, and the average absolute error was 3%.

Recently, sound-based diagnosis systems have been given much attention in many fields due to the advantages of their simple structure, non-touching measurement style, and low-power dissipation. In order to improve the efficiency of coal production and the safety of the coal mining process, accurate information is always essential. It is indicated that the sound signal produced during the cutting process of the coal mining shearer contains much cutting pattern identification information. In this paper, the original acoustic signal is first collected through an industrial microphone. To analyze the signal deeply, an adaptive Hilbert–Huang transform (HHT) was applied to decompose the sound to several intrinsic mode functions (IMFs) to subsequently acquire 1024 Hilbert marginal spectrum points. The 1024 time-frequency nodes were reorganized as a 32 × 32 feature map. Moreover, the LeNet-5 convolutional neural network (CNN), with three convolution layers and two sub-sampling layers, was used as the cutting pattern recognizer. A simulation example, with 10,000 training samples and 2000 testing samples, was conducted to prove the effectiveness of the proposed method. Finally, 1971 testing sound series were recognized accurately through the trained CNN and the proposed method achieved an identification rate of 98.55%.