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Purpose This paper aims to propose a deployment optimization and efficient synchronous acquisition method for compressive stress sensors used by stress distribution law research based on the genetic algorithm and numerical simulations. The authors established a new method of collecting the mining compressive stress-strain distribution data to address the problem of the number of sensors and to optimize the sensor locations in physical similarity simulations to improve the efficiency and accuracy of data collection. Design/methodology/approach First, numerical simulations were used to obtain the compressive stress distribution curve under specific mining conditions. Second, by comparing the mean square error between a fitted curve and simulation data for different numbers of sensors, a genetic algorithm was used to optimize the three-dimensional (3D) spatial deployment of sensors. Third, the authors designed an efficient synchronous acquisition module to allow distributed sensors to achieve synchronous and efficient acquisition of hundreds of data points through a built-in on-board database and a synchronous sampling communication structure. Findings The sensor deployment scheme was established through the genetic algorithm, A synchronous and selective data acquisition method was established for reduced the amount of sensor data required under synchronous acquisition and improved the system acquisition efficiency. The authors obtained a 3D compressive stress distribution when the advancement was 200 m on a large-scale 3D physical similarity simulation platform. Originality/value The proposed method provides a new optimization method for sensor deployment in physical similarity simulations, which improves the efficiency and accuracy of system data acquisition, providing accurate acquisition data for experimental data analysis.

Purpose In this study, a physical similarity simulation plays a significant role in the study of crack evolution and the gas migration mechanism. A sensor is deployed inside a comparable artificial rock formation to assure the accuracy of the experiment results. During the building of the simulated rock formation, a huge volume of acidic gas is released, causing numerous sensor measurement mistakes. Additionally, the gas concentration estimation approach is subject to uncertainty because of the complex rock formation environment. As a result, the purpose of this study is to introduce an adaptive Kalman filter approach to reduce observation noise, increase the accuracy of the gas concentration estimation model and, finally, determine the gas migration law. Design/methodology/approach First, based on the process of gas floatation-diffusion and seepage, the gas migration model is established according to Fick’s second law, and a simplified modeling method using diffusion flux instead of gas concentration is presented. Second, an adaptive Kalman filter algorithm is introduced to establish a gas concentration estimation model, taking into account the model uncertainty and the unknown measurement noise. Finally, according to a large-scale physical similarity simulation platform, a thorough experiment about gas migration is carried out to extract gas concentration variation data with certain ventilation techniques and to create a gas chart of the time-changing trend. Findings This approach is used to determine the changing process of gas distribution for a certain ventilation mode. The results match the rock fissure distribution condition derived from the microseismic monitoring data, proving the effectiveness of the approach. Originality/value For the first time in large-scale three-dimensional physical similarity simulations, the adaptive Kalman filter data processing method based on the inverse Wishart probability density function is used to solve the problem of an inaccurate process and measurement noise, laying the groundwork for studying the gas migration law and determining the gas migration mechanism.