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Solid backfilling scraper conveyor is a key equipment of solid backfilling mining technology, and the degree of its high efficiency and intelligence restricts the development of solid intelligent backfilling mining technology. Currently, it is difficult to break through the bottleneck of high power, super-large mining and high reliability. The operating state is significantly affected by the main controlling factors such as geological conditions and filling process. The problem of autonomous control of abnormal working conditions needs to be solved urgently. The characteristics of solid backfilling scraper conveyor is summarized, and the posture and conveyance state characterization method of solid backfilling scraper conveyor is developed. By analyzing the formation principle of abnormal working conditions, selecting the discriminant index of abnormal working conditions, and combined with the characterization method of posture and conveyance state, the discriminant criteria of abnormal working conditions of the spatial posture and traction state of the scraper conveyor and the adjustment and control path of typical abnormal working conditions are given. The mechanism of conveyance control of solid backfilling scraper conveyor under multi-working conditions is revealed, and the efficient autonomous control method for abnormal working conditions is proposed to real-time control the transportation volume of backfilling materials, the straight line and horizontal extent. The first 260-meter-long solid filling project in China shows that through the autonomous control of abnormal working conditions, for every 100 mm reduction in horizontal offset, the traction is reduced by 85 kN and the transmission power loss is reduced by 55 kW, when the maximum vertical offset is reduced by 100 mm, the conveying power loss can be reduced by 7.2 kW, and for every 100 kN/m reduction in the mass of the cargo per unit length, the traction is reduced by 31.9 kN and the transmission power loss is reduced by 38.2 kW. The proposed autonomous control method of abnormal working conditions can significantly improve the conveying efficiency of solid backfilling scraper conveyor, and can help realize intelligent solid backfilling mining.

Whether the self-demodulation of mechanism interference can be realized in the self-driven execution process of filling operation is the basis for the solid filling hydraulic support to achieve intelligence. Using the theoretical analysis method, taking the ZC5 160/30/50 type solid filling hydraulic support as an example, starting from the geometric and motion constraint relationship of the filling support mechanism, the orthogonal pose control index is established: the horizontal distance and vertical distance of the tamping hinge point top beam, which realizes the pose characterization of the rear top beam of the support under any working condition; The motion characteristics of the bottom-discharge conveyor of the filling support under various working condition factors were analyzed, and the orthogonal pose control index was established: the vertical distance and horizontal distance of the top beam of the bottom-discharge conveyor, which realized the pose characterization of the bottom-discharge conveyor under any working condition; Based on the pose control index of the rear top beam and the bottom-discharge conveyor, the landing position characterization index of the filling material on the coal seam floor during the discharge process is further obtained: the discharge center distance, which realizes the landing position characterization of the filling material under any working condition; the connection relationship and easy interference position of the mechanism action and pose adjustment in each stage of the filling operation process are analyzed, based on the orthogonal pose control index, the interference critical control equation of the discharge and typical collision position under any working condition is established by using the projection method; taking the tamping mechanism rotation angle and tamping cylinder stroke as the characterization of the interference critical curve under typical working conditions, it is proposed to use the three-zone distribution characteristics of “interference zone, easy interference zone, and non-interference zone” to characterize the interference critical degree, and give the demodulation path of each interference state; based on the interference critical control equation, interference three-zone distribution characteristics and the connection relationship of mechanism action and pose adjustment in the filling operation process, an interference state autonomous identification method is proposed: using angle sensor and stroke sensor to obtain the real-time rotation angle and stroke of the tamping mechanism, substituting into the interference critical equation of each easy interference position to obtain the theoretical value and interference critical curve of the tamping mechanism rotation angle or stroke in that position, judging the position of the actual value on the interference critical curve three-zone distribution diagram can realize the autonomous discrimination of interference position and state, and autonomous demodulation can be realized according to the interference three-zone distribution curve diagram; based on the interference position and interference state autonomous identification method, the interference autonomous discrimination and demodulation algorithm is designed. The research results provide new reference indicators for the pose characterization of the filling hydraulic support mechanism, provide basic criteria for the intelligent obstacle avoidance and demodulation of mechanism interference, and provide algorithm basis for the self-driven execution of the filling operation of solid intelligent filling.

In coal mining, solid backfilling technology is widely used. However, its efficiency is seriously hindered by the following two factors. Firstly, the process flow of the solid backfilling operation is more complicated in the back, and the spatiotemporal linkage (SPL) between actions of the cylinders powering each support and between hydraulic supports in the whole face lacks continuity. Secondly, the coal mining process in the front has a higher level of intelligence and technical maturity than the backfilling operation in the back, the latter permanently staying behind the former. To this end, the present study investigates the SPL of the mining and backfilling operations for single supports in the working and whole faces. The SPL of cylinder actions is analyzed for intelligent backfilling using hydraulic supports. We also investigate the SPL of the positions of each piece of key equipment involved in different steps of intelligent backfilling in the whole face. Formulas are derived for calculating the time required to complete the cyclic hydraulic support movement–discharge–filling operation for single supports and the whole face. The key factors influencing the time required to complete a hydraulic support movement–discharge–filling cycle are analyzed. On this basis, a backfilling efficiency optimization scheme is proposed. It envisages reducing the number of tampings and time gaps in actions of single supports and cylinders, increasing the number of hydraulic supports in parallel operation, and intelligent upgrading of the backfilling operation. These findings help synchronize coal mining and backfilling operations.

This paper analyzes the typical technical problems arising from dumping and tamping collision interferences in the working faces of conventional mechanized solid backfilling mining (SBM). Additionally, the technical and consecutive characteristics of the solid intelligent backfilling (SIB) method, the execution device, and the corresponding process categories of the SIB process are analyzed. A design for an SIB process flow is presented. Critical algorithms, including automatic recognition and optimization planning based on the cost function and laying the algorithm foundation, are proposed to develop a backfilling process control system. A joint simulation test system is built on a MATLAB/Simulink simulation toolkit (MSST) to simulate and test the optimized algorithms. The results show that the optimized algorithm can realize the automatic optimization planning and automatic interference-recognition adjustment of the backfilling process under actual engineering conditions. In conclusion, this paper analyzes typical technical problems in the conventional backfilling process, designs the SIB process flow, and develops key algorithms to achieve the automatic control of the backfilling process.

Solid backfilling is an environmentally friendly method of coal mining. Backfilling hydraulic supports are important devices in solid backfill mining. In order to speed up the design and manufacturing process of them, this paper proposes a method of hydraulic support reformation and evaluation. The mechanical models of top-coal caving hydraulic support and backfilling hydraulic support were established to analyze the stress characteristics of the main structure. ABAQUS was used to establish the 3D numerical model to analyze the load-bearing characteristics, as well as verify the strength requirement. In addition, the structural characteristics, compaction characteristics, geological adaptation characteristics, and interference characteristics of the structure were analyzed using motion simulation. After reforming, the ramming force is just above 2.0 MPa, and the utilization ratio of the old parts of the top-coal caving hydraulic support is more than 50%, which saved the costs of the new backfilling hydraulic support and reduced the waste of idle top-coal caving hydraulic support. The successful application of the backfilling hydraulic support in the Tangshan mine showed the rationality of the reform design.