An electrical control method and system for replacing cutting teeth in an open-pit mining machine

Abstract

This application discloses an electrical control method and system for replacing cutting teeth in open-pit mining machines, belonging to the technical field of coal mining equipment. The electrical control method uses an operation box to control a motor to drive the cutting tooth drum to rotate, and then a controller operates a cutting tooth replacement tool to replace the damaged cutting tooth, replacing traditional manual operation. This significantly reduces the intensity of manual operation, shortens the replacement time for a single cutting tooth, and effectively improves replacement efficiency. Simultaneously, this method constructs a proactive safety barrier through a mandatory safety logic of "opening the toolbox triggers a sensor, the sensor transmits a first signal to the controller, and the controller responds and stops the mining machine." When the worker opens the tool storage box to prepare for cutting tooth replacement, the system automatically stops the mining machine, avoiding the risk of accidental drum rotation or component malfunction due to misoperation during traditional manual replacement, thus ensuring the personal safety of workers operating at close range.

Description

Technical Field

[0001] This application belongs to the technical field of coal mining equipment, and in particular relates to an electrical control method and electrical control system for replacing cutting teeth of an open-pit mining machine. Background Technology

[0002] In open-pit mining operations, the cutting teeth of open-pit mining machines, as the core components that come into direct contact with the ore and rock, are subject to continuous impact, friction and wear, and need to be frequently replaced after operation to ensure the normal operation of the mining machine and the quality of mining.

[0003] Currently, the replacement of cutting teeth for open-pit mining machines in the industry still largely relies on traditional manual operation: workers need to use ordinary tools to manually pry and flip the heavy cutting tooth drum to adjust the position of the cutting teeth, and then manually disassemble the damaged cutting teeth and install the new ones. This process not only requires a lot of physical strength and is cumbersome, but each replacement is often time-consuming, seriously slowing down the overall operation of the mining machine and significantly reducing mining efficiency; more importantly, this traditional replacement method poses a high safety risk. During the replacement operation, the open-pit mining machine is not equipped with a dedicated cutting tooth replacement protection system and lacks forced shutdown control logic. If there is a misoperation on site (such as accidentally touching the start button or control lever), it is very easy to cause the mining machine motor to start unexpectedly, the cutting tooth drum to rotate suddenly, or the hydraulic system to malfunction. At this time, the workers are in close contact with the drum and cutting teeth and are very likely to be caught in the rotating parts or injured by tools or cutting teeth, which can easily cause safety hazards. Summary of the Invention

[0004] This application provides an electrical control method and system for replacing cutting teeth in open-pit mining machines. The electrical control method uses an operation box to control a motor to drive a drum rotation, which is then used with a cutting tooth replacement tool to complete the replacement. This significantly reduces physical labor consumption, shortens the time required for each replacement, and significantly improves mining efficiency. Simultaneously, opening the toolbox triggers a sensor, and the controller forces the mining machine to stop. An emergency stop button is also provided to handle abnormalities, preventing risks such as accidental motor start-up or drum rotation due to misoperation. This provides safety assurance for workers operating at close range, balancing operational safety and economy. It solves the problem that current open-pit mining machine cutting tooth replacement relies on manual operation, which is physically demanding, cumbersome, inefficient, and prone to accidental equipment start-up due to the lack of a dedicated protection system, threatening personnel safety.

[0005] In a first aspect, embodiments of this application provide an electronic control method for replacing the cutting teeth of an open-pit mining machine, comprising:

[0006] Open the toolbox containing the cutting tool replacement tool and operation box, trigger the sensor set on the toolbox, so that the sensor generates a first signal and transmits it to the controller;

[0007] After the controller responds to the first signal, it controls the open-pit mining machine to stop operating;

[0008] The operation box sends a first control command to the motor connected to the cutting roller, causing the motor to start running in response to the first control command, so as to drive the cutting roller of the open-pit mining machine to rotate.

[0009] While the cutting tooth roller is rotating, the condition of the cutting teeth on the cutting tooth roller is checked. The condition of the cutting teeth includes a damaged state and a normal state. When it is determined that the cutting tooth is in a damaged state, a second control command is sent to the motor through the operation box so that the motor responds to the second control command and stops running, so that the cutting tooth roller stops rotating.

[0010] After the cutting tooth roller stops rotating, the controller controls the cutting tooth replacement tool to replace the damaged cutting tooth.

[0011] In one feasible implementation, the sensor is a proximity sensor, the toolbox has a shielding function, and opening the toolbox for storing the cutting tool replacement tool and the operation box triggers the sensor located on the toolbox, causing the sensor to generate a first signal and transmit it to the controller, including:

[0012] When the distance between the toolbox and the cutting teeth on the cutting tooth roller is within a preset detection range, opening the toolbox allows the proximity sensor to detect the cutting teeth and generate the first signal.

[0013] When the toolbox is closed, the proximity sensor does not generate the first signal.

[0014] In one feasible implementation, the cutting tooth replacement tool is connected to a power mechanism, which includes a hydraulic pump and an operating valve; the step of replacing the damaged cutting tooth by controlling the cutting tooth replacement tool via the controller after the cutting tooth drum stops rotating includes:

[0015] The controller adjusts the power supplied to the cutting tool by controlling the output pressure of the hydraulic pump and the on / off state of the operating valve.

[0016] In one feasible implementation, the electronic control method further includes an emergency shutdown step;

[0017] When an abnormal situation occurs during the replacement of the cutting tooth using the cutting tooth replacement tool, press the emergency stop button, and the emergency stop button will send a second signal to the controller.

[0018] The controller uses the second signal to stop the open-pit mining machine, the motor, and the power mechanism from operating.

[0019] In one feasible implementation, after the replacement of the damaged cutting tooth is completed, the electronic control method further includes;

[0020] The operation box sends the first control command to the motor again to control the motor to run and drive the cutting tooth roller to continue rotating, and checks the status of the remaining cutting teeth on the cutting tooth roller again.

[0021] If it is determined that there is a new damaged cutting tooth on the cutting tooth roller, a second control command is sent to the motor through the operation box to control the motor to stop running and stop the cutting tooth roller from rotating. Then, the controller controls the cutting tooth replacement tool to replace the new damaged cutting tooth until all cutting teeth on the cutting tooth roller have been inspected and replaced.

[0022] In one feasible implementation, after the inspection and replacement of all cutting teeth on the cutting tooth roller are completed, the electrical control method further includes;

[0023] The controller stops the power mechanism from working.

[0024] Place the cutting tooth replacement tool into the toolbox and close the toolbox; the sensor then stops transmitting the first signal to the controller.

[0025] The controller controls the open-pit mining machine to resume normal operation according to a preset program.

[0026] In one feasible implementation, sending a first control command to a motor connected to the cutting roller via the operation box, causing the motor to start running in response to the first control command, to drive the cutting roller of the open-pit mining machine to rotate, includes:

[0027] When the motor drives the cutting tooth roller to rotate, the rotation parameters of the cutting tooth roller are recorded synchronously; the rotation parameters include the rotation angle or the number of rotations.

[0028] When the rotation parameter reaches the preset value, it is determined that the inspection of all cutting teeth on the cutting tooth roller is completed; the preset value is at least the parameter value corresponding to one revolution of the cutting tooth roller.

[0029] Secondly, this application also provides an electronic control system for changing the cutting teeth of an open-pit mining machine. The electronic control system is used to execute the above-mentioned electronic control method for changing the cutting teeth of an open-pit mining machine. The electronic control system includes a toolbox, a sensor, a control unit, and a drive unit.

[0030] The toolbox is used to store cutting tool replacement tools and an operation box;

[0031] The sensor is mounted on the toolbox and is used to generate a first signal when the toolbox is opened.

[0032] The control unit includes a controller and the operation box; the controller is used to respond to the first signal and control the open-pit mining machine to stop all operations, and the controller is also used to control the open-pit mining machine to resume normal operation; the operation box is used to send a first control command or a second control command to the motor connected to the cutting roller;

[0033] The drive unit includes the motor; when checking the state of the cutting teeth on the cutting tooth roller, the motor is used to start running in response to the first control command and drive the cutting tooth roller to rotate; when it is determined that the cutting teeth are in a damaged state, the motor is used to stop running in response to the second control command and stop the cutting tooth roller from rotating.

[0034] The cutting tooth replacement tool is used to replace the damaged cutting teeth when the cutting tooth roller stops rotating.

[0035] In one feasible implementation, the electronic control system further includes a power unit, which is a power mechanism used to provide power to the cutting tool;

[0036] The power mechanism includes a hydraulic pump and an operating valve. The controller is used to control the output pressure of the hydraulic pump and the on / off state of the operating valve, thereby adjusting the amount of power provided to the cutting tooth replacement tool.

[0037] In one feasible implementation, the electronic control system further includes an emergency stop button for sending a second signal to the controller in case of an abnormal situation;

[0038] The controller is also used to control the open-pit mining machine, the motor, and the power mechanism to stop working in response to the second signal.

[0039] This application provides an electrical control method and system for replacing cutting teeth in open-pit mining machines. The electrical control method uses an operation box to control a motor to drive the cutting tooth drum to rotate, and a controller to control a cutting tooth replacement tool to replace damaged cutting teeth. This replaces the traditional manual disassembly and installation of cutting teeth. The motor can stably drive the drum to rotate to adjust the position of the cutting teeth, eliminating the need for workers to expend physical effort to turn the heavy drum. Using a cutting tooth replacement tool to replace cutting teeth significantly reduces the intensity of manual operation, shortens the time required to replace a single cutting tooth, and effectively improves the efficiency of cutting tooth replacement. This solves the pain points of traditional manual operation being laborious, time-consuming, and affecting work efficiency.

[0040] By employing a mandatory safety logic of "opening the toolbox triggers the sensor, the sensor transmits the first signal to the controller, and the controller responds to the first signal to stop all actions of the mining machine," a pre-emptive safety barrier is constructed for the replacement operation. As soon as the worker opens the toolbox containing the tools to replace the cutting teeth, the system automatically controls the mining machine to stop. This avoids the risk of accidental rotation of the drum or malfunction of parts due to misoperation during the traditional manual replacement of cutting teeth, which is caused by the start of the motor or hydraulic system. It ensures the personal safety of workers when working at close range and solves the problems of danger and significant safety hazards in traditional manual operation. Attached Figure Description

[0041] Figure 1 This is a flowchart of an electrical control method for replacing the cutting teeth of an open-pit mining machine, as provided in this application;

[0042] Figure 2 This is a flowchart of another electrical control method for replacing the cutting teeth of an open-pit mining machine provided in this application;

[0043] Figure 3 This is a schematic diagram of an electrical control system for replacing the cutting teeth of an open-pit mining machine, as provided in this application.

[0044] Figure 4 This is a structural diagram of the control box;

[0045] Figure 5 This is a schematic diagram of the tool for changing cutting teeth.

[0046] Explanation of reference numerals in the attached figures:

[0047] 1-Toolbox; 2-Cutting tooth replacement tool; 3-Operation box; 4-Sensor; 5-Motor; 6-Hydraulic pump; 7-Operating valve; 8-Emergency stop button; 9-Controller; 10-Cutting tooth roller;

[0048] 21-Housing; 22-Driving cylinder; 23-Operating button; 24-Oil pipe. Detailed Implementation

[0049] To enable those skilled in the art to better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of this application.

[0050] Currently, the replacement of cutting teeth for open-pit mining machines still largely relies on traditional manual operation. Manual tooth replacement is labor-intensive, time-consuming, and inefficient. Furthermore, the process carries the risk of accidental injury to workers due to misoperation, posing significant safety hazards and severely hindering the safety and economic efficiency of open-pit mining operations. The electrical control method and system for cutting tooth replacement in this application control the motor to drive the cutting tooth drum rotation via an operation box, and the controller controls the cutting tooth replacement tool to replace damaged cutting teeth. This replaces the traditional manual disassembly and installation of cutting teeth, significantly reducing manual labor intensity, shortening the replacement time for a single cutting tooth, and effectively improving replacement efficiency. Through a forced safety logic of "opening the toolbox triggers a sensor, the sensor transmits a first signal to the controller, and the controller responds to the first signal, stopping all actions of the mining machine," the system automatically stops the mining machine whenever the worker opens the toolbox to replace the cutting teeth, thus ensuring the personal safety of workers operating at close range.

[0051] The following description, in conjunction with the accompanying drawings, details the electrical control method and the specific structure of the electrical control system for replacing the cutting teeth of an open-pit mining machine provided in this application.

[0052] Reference Figure 1 and Figure 2 As shown in the figure, this application provides an electronic control method for replacing the cutting teeth of an open-pit mining machine, including:

[0053] S10: Open the toolbox used to store the cutting tool replacement tool and operation box, trigger the sensor set on the toolbox, so that the sensor generates the first signal and transmits it to the controller;

[0054] When the open-pit mining machine completes a phase of mining operations and the operator determines that the cutting teeth need to be inspected and replaced, they proceed to the toolbox located below the machine's cab. They open the toolbox door, which stores the cutting tooth replacement tools and operating box. At this point, a sensor located on the toolbox door is triggered, generating a first signal, which is transmitted to the PLC controller via a shielded cable. If the sensor is an inductive proximity sensor, and the distance between the toolbox and the cutting teeth is within a preset range, the metal trigger piece will move away from the sensor after the door is opened, and the sensor will generate the first signal. If the toolbox is closed or the distance exceeds the preset range, the sensor will not generate a signal.

[0055] S20: After the controller responds to the first signal, it controls the open-pit mining machine to stop running;

[0056] Upon receiving the first signal, the PLC controller immediately retrieves the preset "cutting tooth replacement safety program" and sends a stop command to the core power system (engine fuel supply circuit, motor drive circuit) and actuators (drum drive device, travel drive device) of the open-pit mining machine; it cuts off the engine start control circuit of the open-pit mining machine, prohibiting engine ignition and starting; it stops the power supply to the drum drive motor to ensure that the drum rotates without inertia; and it locks the travel hydraulic valve group to prevent accidental movement of the equipment. If the controller does not detect equipment stop feedback within 2 seconds, it will trigger an audible and visual alarm to prompt personnel to check the equipment status.

[0057] S30: Send a first control command to the motor connected to the cutting roller via the operation box, so that the motor responds to the first control command and starts running to drive the cutting roller of the open-pit mining machine to rotate;

[0058] The operator retrieves the control box from the toolbox, presses the "Enable" button to unlock operating permissions, and then sends the first control command (PWM speed control signal) to the motor via the "Flip" or "Rotate" buttons. Upon receiving the command, the motor controller adjusts the motor output to a preset speed of 5-10 r / min, driving the cutting roller to rotate slowly. The encoder on the motor output shaft collects data such as rotation angle and speed in real time and feeds it back to the control box display for operator monitoring. The control box has built-in interlocking logic; if the controller is not in "cutting roller replacement mode," button operations are invalid to prevent accidental activation.

[0059] S40: While the cutting tooth drum is rotating, check the condition of the cutting teeth on the cutting tooth drum. The condition of the cutting teeth includes a damaged condition and a normal condition. When it is determined that the condition of the cutting tooth is a damaged condition, send a second control command to the motor through the operation box so that the motor responds to the second control command and stops running, so that the cutting tooth drum stops rotating.

[0060] Workers stand in a safe area 1-1.5 meters away from the drum and inspect each cutting tooth as the drum rotates. The condition of the cutting teeth can be determined according to the "Technical Specification for Maintenance of Coal Mine Electromechanical Equipment" (MT / T1097-2008), specifically: tooth wear exceeding 5mm, tooth shank bending deformation exceeding 2mm, tooth detachment, or gap between the tooth and the cutting tooth holder exceeding 2mm. If a cutting tooth exhibits tooth wear exceeding 5mm, tooth shank deformation, tooth detachment, or a gap between the tooth and the cutting tooth holder exceeding 2mm, it is considered damaged; otherwise, it is considered normal. Upon discovering a damaged cutting tooth, immediately press the "Drum Stop" button on the control box to send a second control command to the motor. After receiving the second control command, the motor controller cuts off the motor power supply and activates the electromagnetic brake, bringing the drum to a complete stop within 3 seconds, with the damaged cutting tooth at an angle of ±15° for easy disassembly. After the motor stops, it sends a feedback signal to the control box, and the display screen simultaneously shows "Drum Stopped".

[0061] S50: After the cutting tooth drum stops rotating, the controller controls the cutting tooth replacement tool to replace the damaged cutting teeth.

[0062] After the operator confirms that the drum has stopped, the controller starts the hydraulic pump and adjusts the output pressure to the appropriate value (e.g., 20MPa). Pressing the "Hydraulic Extension" button on the control box reverses the valve, allowing hydraulic oil to enter the rodless chamber of the cutter replacement tool's cylinder. The piston rod extends and pushes the old cutter's handle. The pressure sensor provides real-time pressure data. When the old cutter loosens and falls off, pressing the "Hydraulic Retraction" button resets the piston rod. The operator then uses snap ring pliers to remove the snap ring from the cutter holder, installs the new cutter, and resets the snap ring, completing the replacement of a single cutter.

[0063] In one embodiment, the sensor is a proximity sensor, and the toolbox has a shielding function. Opening the toolbox, which stores the cutting tool changer and the operation box, triggers the sensor located on the toolbox, causing the sensor to generate a first signal and transmit it to the controller, including:

[0064] When the distance between the toolbox and the cutting teeth on the cutting tooth drum is within the preset detection range, opening the toolbox will allow the proximity sensor to detect the cutting teeth and generate a first signal.

[0065] When the toolbox is closed, the proximity sensor does not generate the first signal.

[0066] The sensor used is an E2E-X3D1-N model inductive proximity sensor. The toolbox has a galvanized steel shell with internal electromagnetic shielding cotton to reduce electromagnetic interference. The sensor is mounted on the side of the toolbox door using a fixed bracket, with the detection end facing the metal trigger plate on the door side, and a suitable detection distance is preset. When the toolbox is in its normal installation position, opening the door moves the metal trigger plate away from the sensor, eliminating eddy current interference in the coil's magnetic field, and the sensor generates the first signal. Closing the door moves the metal trigger plate into the detection range, and the sensor stops generating the first signal. If the toolbox moves out of the preset distance, even if the door is opened, the sensor will not generate a signal.

[0067] In some embodiments, the cutting tooth replacement tool is connected to a power mechanism, which includes a hydraulic pump and an operating valve; after the cutting tooth drum stops rotating, the cutting tooth replacement tool is controlled by a controller to replace the damaged cutting tooth, including:

[0068] The controller adjusts the power supplied to the cutting tool by controlling the output pressure of the hydraulic pump and the on / off state of the operating valve.

[0069] The hydraulic pump of the power mechanism is a variable displacement piston pump with a rated pressure of 31.5 MPa and a displacement of 5-20 mL / r. The operating valve is a two-position four-way solenoid directional valve. The controller controls the hydraulic pump displacement and adjusts the output pressure via a proportional solenoid (e.g., 18 MPa when replacing with a 30 mm diameter cutting tooth, and 22 MPa for a 40 mm diameter cutting tooth). Simultaneously, it controls the on / off state and reversal of the operating valve: pressing the "Hydraulic Extension" button energizes the operating valve, allowing hydraulic oil to enter the rodless chamber of the cylinder, extending the piston rod; pressing the "Hydraulic Retraction" button reverses the energization, allowing hydraulic oil to enter the rod chamber of the cylinder, retracting the piston rod; pressing the "Hydraulic Stop" button de-energizes the operating valve, stopping the oil supply. The entire process is precisely controlled by electrical signals to prevent damage to components due to improper pressure.

[0070] The procedure for replacing damaged cutting teeth includes:

[0071] Use tools such as snap ring pliers to remove the snap ring from the cutting tooth holder;

[0072] Fix the cutting tooth replacement tool on the cutting tooth holder and align the hydraulic cylinder with the tail of the old cutting tooth shank.

[0073] The control valve is opened via the controller, and the hydraulic pump is started.

[0074] Press the "Extend" button on the control box to extend the cylinder piston rod and evenly push the old cutting teeth:

[0075] After the old cutting tooth loosens and falls out of the cutting tooth holder, stop applying pressure and then press the retraction button to reset the cylinder piston rod.

[0076] After removing the damaged cutting tooth from the cutting tooth holder, the new cutting tooth in good condition can be installed on the cutting tooth holder to complete the replacement.

[0077] In some embodiments, the electronic control method further includes an emergency shutdown step;

[0078] If an abnormal situation occurs during the replacement of the cutting teeth using the cutting tooth replacement tool, press the emergency stop button, and the emergency stop button will send a second signal to the controller.

[0079] The controller uses a second signal to stop the open-pit mining machine, motor, and power mechanism from operating.

[0080] Abnormal situations include unexpected motor start-up, hydraulic pressure exceeding 30MPa, unauthorized rotation of the drum, or workers approaching rotating parts, or tools falling off. The emergency stop button can be located on the control box. Pressing it sends a low-level second signal to the controller, which immediately executes an emergency stop: cutting off engine ignition power, motor drive power (starting the brake), and hydraulic pump power, triggering an audible and visual alarm. After the emergency stop, the emergency stop button must be manually unlocked, and "Abnormality Cleared" must be confirmed on the controller interface to release the shutdown status.

[0081] like Figure 2 As shown, in some embodiments, after the replacement of the damaged cutting tooth is completed, the electronic control method further includes;

[0082] The first control command is sent to the motor again through the operation box to control the motor to drive the cutting tooth drum to continue rotating, and the status of the remaining cutting teeth on the cutting tooth drum is checked again.

[0083] If a new damaged cutting tooth is found on the cutting tooth roller, a second control command is sent to the motor through the operation box to stop the motor and stop the cutting tooth roller from rotating. Then, the cutting tooth replacement tool is controlled by the controller to replace the new damaged cutting tooth until all cutting teeth on the cutting tooth roller have been inspected and replaced.

[0084] After replacing a single cutting tooth, the operator presses the "flip" or "rotate" button on the control box. The motor drives the drum to continue rotating, and the encoder provides real-time feedback on the rotation parameters. The operator then checks the remaining cutting teeth one by one along the circumference of the drum, paying particular attention to the cutting teeth adjacent to the replacement location. If a new damaged cutting tooth is found, the machine is immediately stopped and replaced, repeating steps S40-S50. After replacement, the drum is restarted until all cutting teeth have been checked, ensuring that no damaged parts are missed.

[0085] In some embodiments, after the inspection and replacement of all cutting teeth on the cutting tooth roller are completed, the electrical control method further includes;

[0086] The power mechanism is stopped by controlling the controller.

[0087] Place the cutting tool into the toolbox and close the toolbox; the sensor will stop transmitting the first signal to the controller.

[0088] The controller restores the open-pit mining machine to normal operation according to the preset program.

[0089] After all cutting teeth have been inspected and replaced, the operator sends a "Work Complete" command through the control box. The controller cuts off the power to the hydraulic pump and closes the control valve to release pressure to atmospheric pressure. The tools are cleaned and returned to the toolbox (tools in the recess, control box in the slot), the box door is closed, and the sensors stop sending the first signal. After the controller checks that the emergency stop button is unlocked and all systems have stopped, it gradually restores the engine start, motor, and travel drive permissions. The display shows "Cutting teeth replacement complete, equipment normal." After confirmation, the operator starts the mining machine and resumes work.

[0090] like Figure 2 As shown, in some embodiments, a first control command is sent to a motor connected to the cutting roller via an operation box, causing the motor to start running in response to the first control command, thereby driving the cutting roller of the open-pit mining machine to rotate, including:

[0091] When the motor drives the cutting tooth drum to rotate, the rotation parameters of the cutting tooth drum are recorded synchronously; the rotation parameters include the rotation angle or the number of rotations.

[0092] When the rotation parameters reach the preset value, it is determined that the inspection of all cutting teeth on the cutting tooth roller is complete; the preset value is at least the parameter value corresponding to one revolution of the cutting tooth roller.

[0093] A 1024-line encoder is installed on the motor output shaft. The controller calculates the roller rotation angle and number of revolutions based on the motor-to-roller transmission ratio (e.g., 10:1) and displays it on the operation box screen. The preset value is set to the parameter for one rotation of the roller (360° or 1 revolution). When the rotation parameter reaches the preset value: if the cutting teeth have not been replaced without stopping the machine, the inspection is considered complete; if the cutting teeth have been replaced, the difference between the stopping position and the preset value is calculated, and the drive motor is used to rotate the corresponding angle to ensure that all cutting teeth are inspected.

[0094] Reference Figures 3-5 As shown, this application embodiment provides an electronic control system for changing the cutting teeth of an open-pit mining machine. The electronic control system is used to execute the above-mentioned electronic control method for changing the cutting teeth of an open-pit mining machine. The electronic control system includes a toolbox 1, a sensor 4, a control unit, and a drive unit.

[0095] Toolbox 1 is used to store the cutting tool replacement tool 2 and the operation box 3;

[0096] Sensor 4 is mounted on toolbox 1 and is used to generate a first signal when toolbox 1 is opened; the control unit includes controller 9 and operation box 3; controller 9 is used to respond to the first signal and control the open-pit mining machine to stop all actions, and controller 9 is also used to control the open-pit mining machine to resume normal operation; operation box 3 is used to send a first control command or a second control command to motor 5 connected to the cutting tooth drum 10.

[0097] The drive unit includes a motor 5; when checking the condition of the cutting teeth on the cutting tooth roller 10, the motor 5 is used to start running in response to the first control command and drive the cutting tooth roller 10 to rotate; when it is determined that the cutting tooth is in a damaged state, the motor 5 is used to stop running in response to the second control command and stop the cutting tooth roller 10 from rotating; the cutting tooth replacement tool 2 is used to replace the damaged cutting tooth when the cutting tooth roller 10 stops rotating.

[0098] The electronic control system includes toolbox 1, sensor 4, control unit and drive unit;

[0099] Toolbox 1 is located below the cab of the open-pit mining machine. It is made of galvanized steel plate and lined with electromagnetic shielding cotton, providing dustproof, waterproof, and electromagnetic interference resistance. The toolbox is divided into a tool storage area and an operation box fixing area. The tool storage area is used to store the cutting tooth replacement tool 2 and auxiliary tools such as snap ring pliers. The operation box fixing area is equipped with a slot and signal interface for fixing the operation box 3 and enabling its signal connection with the control unit. A metal trigger plate is installed on the side of the toolbox 1 door, which works with the sensor 4 to detect the door status.

[0100] Sensor 4 includes an inductive proximity sensor, which is equipped with a signal shielded cable and a mounting bracket. The inductive proximity sensor model is E2E-X3D1-N or IME08-04NPSZC0S. It is mounted on the door side of toolbox 1 via the mounting bracket, with its detection end facing the metal trigger plate on the door side. Sensor 4 integrates a high-frequency oscillation circuit, a detection coil, and a signal processing module. It can identify the open / closed state of the door through changes in magnetic field eddy currents and generate a switching signal. One end of the signal shielded cable is connected to sensor 4, and the other end is connected to controller 9 for signal transmission and reduction of electromagnetic interference.

[0101] The control unit consists of controller 9 and operation box 3. Controller 9 adopts PLC (programmable logic controller) and has a built-in cutter replacement safety program and parameter storage module. It can receive signals from sensor 4, operation box 3 and emergency stop protection unit, and send control commands to drive unit and power unit.

[0102] like Figure 4 As shown, the control box 3 has four buttons on its surface, from left to right: "Emergency Stop," "Enable / Disable," "Flip," and "Rotate." The control box 3 integrates a microcontroller, an RS485 signal transceiver chip, a power conversion module, and a status display module. Externally, it forms a bidirectional connection with the controller 9, motor controller, and hydraulic system via shielded cables. When an operator presses any function button, the internal contacts close / open, triggering a change in the GPIO pin level of the MCU. The MCU interprets this into a corresponding control command (e.g., "Flip" corresponds to "Motor 5 drives the drum to rotate clockwise") through a preset program. This command is then converted into an RS485 differential signal by the signal transceiver chip and transmitted to the controller 9. After verifying the command's validity, the controller 9 sends an execution signal to the motor controller or hydraulic system, while simultaneously sending feedback data such as "motor speed," "drum position," and "system status" back to the control box 3. The MCU processes this data and displays it on the screen in real time, ensuring the operator can clearly monitor the work progress.

[0103] The "Enable / Disable" button acts as the "master switch" for system startup. When "Enable" is pressed, the MCU sends an "Allow Operation" signal to the controller 9, and the controller 9 unlocks the control permissions of the motor 5 and the hydraulic system. Only then can the "Flip" and "Rotate" buttons take effect. When pressed again, the permissions are immediately locked, and the "Flip" and "Rotate" button operations are invalid to avoid accidental touches that could cause the equipment to operate.

[0104] The "flip" and "reverse" buttons are interlocked and used to control the direction of rotation of the cutting roller 10: when the "flip" button is pressed, the MCU sends a "roller rotates clockwise" command, the controller 9 drives the motor 5 to run in the forward direction, and the encoder collects the rotation angle in real time and feeds it back to the operation box 3; when the "reverse" button is pressed, the MCU sends a "roller rotates counterclockwise" command, the motor 5 runs in the reverse direction, and only one direction command can be triggered at a time to prevent the motor 5 from being damaged due to conflict between forward and reverse rotation.

[0105] The "Emergency Stop" button is independent of other buttons. When pressed, it does not require "Enable" permission verification. The MCU directly sends an "Emergency Stop" signal to the controller 9 (dual-channel signal redundancy transmission to avoid single-channel failure). The controller 9 immediately cuts off the power supply to the motor 5, stops the hydraulic pump 6, and triggers an audible and visual alarm. At the same time, the display screen of the operation box 3 shows "Emergency Stop Triggered, Equipment Stopped" in flashing red font, ensuring that power is quickly cut off in case of sudden danger.

[0106] The drive unit includes a motor 5, a motor controller, and an encoder. The motor 5 is a slow-speed motor, which is a permanent magnet synchronous motor with a rated speed of 5-10 r / min. Its output torque is adapted to the rotation requirements of the cutting roller 10. It is connected to the cutting roller 10 through a reducer. The motor controller receives the PWM speed regulation signal from the controller 9 and adjusts the output speed and direction of the motor 5. The encoder is installed on the output shaft of the motor 5 with a resolution of not less than 1024 lines. It collects the rotation angle signal of the motor 5 in real time and transmits it to the controller 9 to convert it into the rotation parameters of the cutting roller 10.

[0107] When the open-pit mining machine completes a phase of mining operations and the operator determines that the cutting teeth need to be inspected and replaced, they go to the toolbox 1 located under the machine's cab and open the door of the toolbox 1, which stores the cutting tooth replacement tools 2 and the operation box 3. At this time, the sensor 4 installed on the door of the toolbox 1 is triggered, generating a first signal, which is transmitted to the controller 9 through a shielded cable. After receiving the first signal, the controller 9 immediately retrieves the preset "cutting tooth replacement safety program" and sends a stop command to the core power system and actuators of the open-pit mining machine to prevent the equipment from moving unexpectedly. The operator takes out the operation box 3 from the toolbox 1 and sends a first control command to the motor 5 connected to the cutting tooth drum 10 through the function buttons on the operation box 3. After receiving the first control command, the motor controller adjusts the output speed of the motor 5 according to the preset parameters, driving the cutting tooth drum 10 to rotate slowly and smoothly. The operator stands in a safe operating area, for example, 1-1.5 meters away from the drum, and checks the status of each cutting tooth as the drum slowly rotates. When a damaged cutting tooth is found, the operator immediately presses the "emergency stop" or "stop" button on the operation box 3 to send a second control command (emergency stop power cut signal) to the motor 5. After receiving the instruction, the motor controller immediately cuts off the power supply to the motor 5 and activates the motor 5 braking device (such as an electromagnetic brake) to completely stop the roller from rotating. After confirming that the cutting tooth roller 10 has stopped rotating, the operator controls the cutting tooth replacement tool 2 through the controller 9 to replace the damaged cutting tooth.

[0108] In some embodiments, the electronic control system further includes a power unit, which is a power mechanism for providing power to the cutting tool 2; the power mechanism includes a hydraulic pump 6 and an operating valve 7, and a controller 9 is used to control the output pressure of the hydraulic pump 6 and the on / off state of the operating valve 7, thereby adjusting the amount of power provided to the cutting tool 2.

[0109] The power mechanism is a hydraulic power mechanism, including a hydraulic pump 6 and an operating valve 7; the cutting tooth replacement tool 2 includes a housing 21, and a drive cylinder 22, an operating button 23 and an oil pipe 24 disposed on the housing 21.

[0110] The shell 21 is made of 45 steel forged main frame and Q235 steel plate protective cover, with IP65 protection level and ≥50kN load-bearing capacity. It provides a stable installation foundation for internal components and can isolate dust and slag and withstand the jacking reaction force.

[0111] like Figure 5As shown, the upper part of the housing 21 integrates a drive cylinder 22. The cylinder barrel can be made of 20# seamless steel pipe, and the piston rod is made of 40Cr chrome-plated material. The stroke can be 50-80mm, and the rated thrust can be 15-25kN. It can match the interference fit disassembly requirements of different models of cutting teeth. The lower part of the housing 21 is equipped with an operation button 23, which can be a waterproof two-position three-way tactile button. The housing 21 can also be equipped with an adjustable positioning component for fixing. The adjustable positioning component can be 2-3 positioning claws, with an adjustment range of 0-50mm. After fitting against the side of the cutting tooth seat, it is locked in place by high-strength bolts. The housing 21 is also equipped with auxiliary structures such as a quick oil pipe interface, a pressure gauge, and an engineering plastic handle.

[0112] The drive cylinder 22 is connected to the quick oil pipe interface of the hydraulic pump 6 through the oil pipe 24, and the operating valve 7 is set on the oil pipe 24; the operating button 23 is connected to the digital input interface of the controller 9 through the shielded twisted pair cable, and the output of the controller 9 is connected to the electromagnetic coil of the operating valve 7 to realize command transmission and valve group control.

[0113] The rated working pressure of the hydraulic pump 6 is 31.5MPa, and the displacement can be adjusted by the controller 9. The operating valve 7 is a solenoid directional valve, which can be a two-position four-way valve to control the flow of hydraulic oil and realize the extension and retraction of the tool cylinder. A pressure sensor is installed on the hydraulic pipeline. The pressure sensor detects the pipeline pressure in real time and transmits it to the controller 9. When the pressure exceeds the preset threshold, protection is triggered.

[0114] When replacing a damaged cutting tooth, use tools such as snap ring pliers to remove the snap ring on the cutting tooth holder, fix the cutting tooth replacement tool 2 on the cutting tooth holder, align the hydraulic cylinder with the tail of the old cutting tooth shank, open the operating valve 7 through the controller 9, start the hydraulic pump 6, press the "extend" button on the operating box 3 to extend the hydraulic cylinder piston rod, and push the old cutting tooth evenly. When the old cutting tooth loosens and falls out of the cutting tooth holder, stop pressurizing, and then press the retraction button to reset the hydraulic cylinder piston rod. After removing the damaged cutting tooth from the cutting tooth holder, the new cutting tooth in good condition can be installed on the cutting tooth holder to complete the replacement.

[0115] In some embodiments, the electronic control system further includes an emergency stop button 8 for sending a second signal to the controller 9 in case of an abnormal situation; the controller 9 is also used to control the open-pit mining machine, the motor 5 and the power mechanism to stop working in response to the second signal.

[0116] The emergency stop button 8 is located in the control box 3 or the cab of the open-pit mining machine. It has a self-locking function. When pressed, it sends a second signal to the controller 9. The second signal is a low-level switching signal. After receiving the second signal, the controller 9 immediately cuts off the power supply to the drive unit, the power unit and the core power system of the open-pit mining machine, and at the same time triggers the sound and light alarm device to work.

[0117] It is readily understood that, based on the several embodiments provided in this application, those skilled in the art can combine, split, or reorganize the embodiments of this application to obtain other embodiments, none of which exceed the protection scope of this application.

[0118] The above detailed embodiments further illustrate the purpose, technical solution, and beneficial effects of the embodiments of this application. It should be understood that the above are merely specific embodiments of the embodiments of this application and are not intended to limit the protection scope of the embodiments of this application. Any modifications, equivalent substitutions, improvements, etc., made on the basis of the technical solutions of the embodiments of this application should be included within the protection scope of the embodiments of this application.

Claims

1. An electrically controlled method of replacing a pick of a surface miner, characterized in that, The method comprises: opening a tool box for storing a cutting tooth replacement tool and an operation box, triggering a sensor arranged on the tool box, so that the sensor generates a first signal and transmits the first signal to a controller; after the controller responds to the first signal, controlling the surface mining machine to stop running; sending a first control instruction to a motor connected with the cutting tooth drum through the operation box, so that the motor starts running in response to the first control instruction to drive the cutting tooth drum of the surface mining machine to rotate; checking the state of the cutting tooth on the cutting tooth drum under the rotation of the cutting tooth drum, the state of the cutting tooth including a damaged state and a normal state, and when it is determined that the state of the cutting tooth is the damaged state, sending a second control instruction to the motor through the operation box, so that the motor stops running in response to the second control instruction, and the cutting tooth drum stops rotating; after the cutting tooth drum stops rotating, controlling the cutting tooth replacement tool to replace the cutting tooth in the damaged state through the controller; wherein after the replacement of the cutting tooth in the damaged state is completed, the electric control method further comprises: sending the first control instruction to the motor through the operation box again, controlling the motor to run to drive the cutting tooth drum to continue rotating, and checking the state of the remaining cutting tooth on the cutting tooth drum again; if it is determined that there is a new cutting tooth in the damaged state on the cutting tooth drum, sending the second control instruction to the motor through the operation box, controlling the motor to stop running and the cutting tooth drum to stop rotating, and then controlling the cutting tooth replacement tool to replace the new cutting tooth in the damaged state through the controller, until all the cutting teeth on the cutting tooth drum are checked and replaced; the method of sending the first control instruction to the motor connected with the cutting tooth drum through the operation box, so that the motor starts running in response to the first control instruction to drive the cutting tooth drum of the surface mining machine to rotate, comprises: when the motor drives the cutting tooth drum to rotate, synchronously recording a rotation parameter of the cutting tooth drum; the rotation parameter includes a rotation angle or a rotation number of turns; when the rotation parameter reaches a preset value, it is determined that the checking of all the cutting teeth on the cutting tooth drum is completed; the preset value is at least a parameter value corresponding to one rotation of the cutting tooth drum.

2. An electrically controlled method of pick change for a surface miner according to claim 1, characterized in that, The sensor is a proximity sensor, and the tool box has a shielding function. The method of opening the tool box for storing the cutting tooth replacement tool and the operation box, triggering the sensor arranged on the tool box, so that the sensor generates the first signal and transmits the first signal to the controller, comprises: when the tool box is within a preset detection range from the cutting tooth on the cutting tooth drum, opening the tool box can make the proximity sensor detect the cutting tooth and generate the first signal; when the tool box is closed, the proximity sensor does not generate the first signal.

3. The electrically controlled method of drag bit replacement for a surface miner according to claim 1, characterized in that, The cutting tooth replacement tool is connected with a power mechanism, and the power mechanism comprises a hydraulic pump and an operation valve. The method of controlling the cutting tooth replacement tool to replace the cutting tooth in the damaged state through the controller after the cutting tooth drum stops rotating, comprises: The controller is configured to control the output pressure of the hydraulic pump and the on-off state of the operation valve, so as to adjust the power provided for the pick replacing tool.

4. An electrically controlled method of pick change for a surface miner according to claim 3, characterized in that, The method further comprises an emergency stop step; When an abnormal situation occurs during the replacement of the pick by the pick replacing tool, an emergency stop button is pressed, and the emergency stop button sends a second signal to the controller; The controller is configured to control the surface mining machine, the motor and the power mechanism to stop working according to the second signal.

5. The electrically controlled method of drag bit replacement for a surface miner according to claim 1, characterized in that, After the inspection and replacement of all picks on the pick roller are completed, the electric control method further comprises: The controller controls the power mechanism to stop working; The pick replacing tool is placed in the tool box, and the tool box is closed, and the sensor stops transmitting the first signal to the controller; The controller controls the surface mining machine to resume normal work according to a preset program.

6. An electric control system for pick change of a surface miner, characterized in that The electric control method for the replacement of the pick of the surface mining machine according to any one of claims 1-5, the electric control system comprising: a tool box for storing the pick replacing tool and the operation box; a sensor arranged on the tool box and configured to generate a first signal when the tool box is opened; a control unit comprising a controller and the operation box; the controller is configured to control the surface mining machine to stop all actions in response to the first signal, and the controller is further configured to control the surface mining machine to resume normal work; the operation box is configured to send a first control instruction or a second control instruction to the motor connected to the pick roller; a driving unit comprising the motor; when the state of the pick on the pick roller is inspected, the motor is configured to start running in response to the first control instruction and drive the pick roller to rotate; when it is determined that the state of the pick is a damaged state, the motor is configured to stop running in response to the second control instruction and stop the pick roller from rotating; the pick replacing tool is configured to replace the pick in the damaged state when the pick roller stops rotating.

7. The electrical control system for drag bit change of a surface miner according to claim 6, characterized in that, a power unit, which is a power mechanism, configured to provide power for the pick replacing tool; the power mechanism comprises a hydraulic pump and an operation valve, and the controller is configured to control the output pressure of the hydraulic pump and the on-off state of the operation valve, so as to adjust the power provided for the pick replacing tool.

8. The electrical control system for drag bit change of a surface miner according to claim 7, characterized in that, an emergency stop button configured to send a second signal to the controller in an abnormal situation; the controller is further configured to control the surface mining machine, the motor and the power mechanism to stop working in response to the second signal.

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