Authors: P.V. Cherkasov, E.A. Balovnev, A.N. Starodubov

Title of the article: Digital model and physical equipment data streams integration algorithm development for a mechanized complex with controlled output

Year: 2025, Issue: 6, Pages: 182-190

Branch of knowledge: 2.8.8 Geotechnology, mining machines

Index UDK: 622 + 004.942

DOI: 10.26730/1999-4125-2025-6-182-190

Abstract: One of the top priorities for the coal industry's development is the implementation of technologies that minimize personnel presence at the longwall face. This is particularly relevant when mining thick seams with hard-to-recover reserves in the roof strata. In the context of the transition to robotic production and the implementation of the "Industry 4.0" concept, the creation of such autonomous systems becomes a strategic objective. This work is devoted to the development of a data integration algorithm for the control system of a mechanized complex with controlled output, designed to automate the process of coal discharge onto the face conveyor. The research focuses on the process of coordinated control of powered roof support sections based on information from monitoring subsystems for feeder performance and analysis of the mined material composition. The article presents the principles of the algorithm's operation, which is based on the analysis of input data from both a digital model and physical sensors. This sensor suite includes a machine vision system for calculating the volume of mined material and a gamma-ray method for identifying waste rock. The structural diagram of the interaction between the virtual and physical spaces, which enables automated output control, is described. Furthermore, the work details the algorithm's decision-making logic, which adjusts the operating modes of the feeder and the flap gate when monitored parameters deviate from specified optimal values. Thus, the developed algorithm enables the implementation of an optimal controlled output regime, minimizing coal dilution and conveyor overload. The proposed solution formalizes the control process and establishes a foundation for implementing a digital twin of a robotic longwall complex. This contributes to enhanced safety and efficiency in underground mining.

Key words: rock mass high coal releasing operation system digital twin digital model control algorithm machine vision system rock mass consistence gamma-ray

Receiving date: 25.09.2025

Approval date: 15.11.2025

Publication date: 22.12.2025

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