ArticleSensors (Basel, Switzerland)2026
Virtual Sensing of Unmeasured Supply-Return Disturbances for Predictive Control in Cooperative Hydraulic Support Pushing.
Article in Sensors (Basel, Switzerland), 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
Cooperative pushing of hydraulic supports is affected by pressure-boundary fluctuations and neighboring-branch actions transmitted through shared supply-return circuits. In longwall mining systems, common-node pressures and neighboring-branch flow disturbances are difficult to measure continuously, which limits their use in feedback predictive control. This study proposes a virtual-sensing-based output -feedback predictive control method for cooperative hydraulic support pushing under limited sensing conditions. A control-oriented coupled model is established by retaining the two-chamber pressure dynamics of the target cylinder, supply-main impedance, common return-main dynamics, and equivalent neighboring supply-side and return-side disturbance flows. The equivalent disturbance flows are introduced as nodal disturbance inputs in the supply and return pressure dynamics. A linear extended state observer reconstructs the common supply-node pressure, common return-node pressure, and equivalent neighboring-disturbance flows from target-cylinder measurements, including displacement, velocity, cap-end pressure, and rod-end pressure. The reconstructed variables are incorporated into an output-feedback model predictive controller to coordinate displacement tracking, velocity stabilization, pressure-boundary regulation, and valve-input smoothing under input-amplitude, input-increment, and output constraints. The method is validated using AMESim-MATLAB/Simulink co-simulation and a dual-branch hydraulic experimental platform. Co-simulation results show that the proposed controller gives a maximum velocity deviation of 1.7484 mm/s, a recovery time of 0.112 s within the 1% velocity error band, and an input total variation of 2.3383. Experimental results show that controller intervention reduces the maximum velocity fluctuation from 1.0041 mm/s to 0.3011 mm/s and shortens the recovery time from 0.505 s to 0.038 s. The results demonstrate that virtual sensing of supply-return pressure boundaries and equivalent neighboring-disturbance flows improves motion continuity and driving-pressure stability in cooperative hydraulic actuation under limited sensing conditions.
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