Bagged mine solid waste system for gob-side entry retaining rapid roadside flexible formwork support

Abstract

The invention relates to the technical field of mine supporting, in particular to a bagged mine solid waste system for gob-side entry retaining rapid roadside flexible formwork supporting, which comprises a supporting device arranged in a haulage roadway and an air return roadway, and the supporting device is composed of a temporary supporting assembly and a flexible formwork supporting assembly. The temporary supporting assembly comprises a first supporting top plate, an X-shaped movable support, a horizontal hydraulic rod, a first vertical hydraulic rod and the like and is used for dynamically following and temporarily supporting the top plate, and the flexible formwork supporting assembly is connected with the temporary supporting assembly through the horizontal hydraulic rod and comprises a second supporting top plate, a second supporting bottom plate and a bagged mine solid waste and displacement monitoring sensor. According to the invention, synchronous propulsion of supporting and mining is realized, and the construction efficiency and safety are improved; mine solid waste is used as a filling material, and resource utilization and environmental protection benefits are achieved; the flexible wall body can adapt to surrounding rock deformation, the monitoring system guarantees long-term stability of supporting, and remarkable practical value and economical efficiency are achieved.

Description

Technical Field

[0001] This invention relates to the field of mine support technology, and in particular to a bagged mine solid waste system for rapid roadway side flexible formwork support along goaf retention. Background Technology

[0002] Mineral resources are a crucial strategic resource for my country, widely used in aerospace, new energy, national defense, electronics, and energy storage, among other fields. The mining and beneficiation processes generate a large amount of solid waste—mineral tailings. my country's annual mineral mining scale is enormous, resulting in tens of millions of tons of mineral tailings. Currently, only a small amount of coarse-grained tailings is used for constructing tailings dams, filling mined-out areas, and making building materials; the majority, due to its fine particle size, must be stored in tailings ponds for extended periods.

[0003] my country has a huge energy consumption demand, and coal mining bears an important mission. The goaf retention technology, as a pillarless mining technology with low tunneling rate and high recovery rate, is based on the principle of preserving and maintaining the original roadway behind the coal face along the coal seam strike, and using it as the roadway for the next working face, thereby achieving safe and efficient mining.

[0004] Drawing on geotextile technology, mineral tailings are filled into geotextile bags to form flexible infill walls, which are used for roadway support in goaf-side retention. Using geotextile bags as a carrier to construct flexible walls from mineral tailings not only enables the resource utilization of mineral tailings, reduces the storage pressure of tailings ponds and reduces dust pollution, but also, thanks to the high strength and high elongation of geotextile bags, can adapt to large deformations of the surrounding rock, improving the economic and social benefits of coal mining. However, current research on the application of geotextile bags in roadway support in goaf-side retention is limited, and existing studies mostly use flexible concrete with low unit area mass of the bags, resulting in high costs and significant construction difficulties. Summary of the Invention

[0005] To overcome the shortcomings of existing technologies, this invention provides a bagged mine solid waste system for rapid roadway side flexible formwork support in goaf retention.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a bagged mine solid waste system for rapid roadway side flexible formwork support in goaf retention roadways, comprising a transport roadway located near the lower section and a return air roadway located near the upper section. Both the transport roadway and the return air roadway are equipped with a bagged mine solid waste device for rapid roadway side flexible formwork support. The bagged mine solid waste device for rapid roadway side flexible formwork support includes a first supporting top plate, and a temporary support assembly is provided on the first supporting top plate. The temporary support assembly includes an X-shaped movable bracket, a metal limiting groove, a first supporting bottom plate, a first vertical hydraulic rod, a hydraulic metal support, and a horizontal hydraulic rod.

[0007] The horizontal hydraulic rod is also equipped with a flexible mold support assembly, which includes a second support top plate, a second support bottom plate, a second vertical hydraulic rod, metal gaskets, bagged mine solid waste, and displacement monitoring wires.

[0008] Preferably, the top of the first support base plate is provided with a pushing and lifting assembly, which includes a fixed cover, a movable cover and a top cover. Fixed covers are fixedly installed at both ends of the top of the first support base plate. A first connecting seat is fixedly installed at the center of the bottom of each fixed cover. A first arc-shaped arm is movably connected to the first connecting seat. The movable cover moves around the top outer periphery of the fixed cover. A supporting rotating rod is movably connected between the movable covers. Rotating arms are fixedly installed at both ends of the supporting rotating rod, and the rotating arms move inside the movable cover.

[0009] A top cover is fixedly installed at the bottom of the first support top plate, and the top cover is movable around the outer periphery of the movable cover. A second connecting seat is fixedly installed at the center of the inner top of the top cover. A second arc-shaped arm is movably connected to the second connecting seat. The first arc-shaped arm and the second arc-shaped arm are respectively movably connected to the two ends of the rotating arm. A motor plate is fixedly installed on the inner side of the movable cover near the transport tunnel. A servo motor is fixedly installed on the top of the motor plate, and the output end of the servo motor is fixedly installed on the top of the support rotating rod.

[0010] Preferably, the first support top plate is provided with an expansion assembly, which includes a support screw, a movable block, a hinge rod, and a side block. The support screw is movably connected to the center of the first support top plate, and the movable block is threaded through the support screw. Movable plates are fixedly installed on both sides of the movable block. L-shaped limiting rods are fixedly installed around the inside of the first support top plate, and a moving plate is movably connected between the L-shaped limiting rods. The moving plate is horizontal with the support screw. The two ends of the movable plate are movably connected to the moving plate through hinge rods. Connecting rods are fixedly installed at both ends of the moving plate on the side away from the support screw, and the connecting rods extend through to the outside of the first support top plate at the end away from the support screw. Side blocks are fixedly installed between the top ends of the connecting rods.

[0011] One end of the support screw extends through to the outside of the first support top plate, and a rotating handle is fixedly installed at the top of the support screw. A connecting plate is fixedly installed at the end of the moving plate away from the rotating handle, and the connecting plate extends through to the outside of the first support top plate. A square base block is fixedly installed between the tops of the connecting plates.

[0012] Preferably, the flexible formwork support assembly is extended by a horizontal hydraulic rod, and extends synchronously with the temporary support assembly as the mining face advances, thereby continuously increasing the support length of the flexible formwork support assembly.

[0013] Preferably, the transport tunnel is equipped with a conveyor belt and mine car rails.

[0014] Preferably, the bagged mine solid waste in the flexible mold support assembly has a length × width of 80cm × 40cm and adopts a crisscrossing and interlocking manner. The geotextile bag structure of the bagged mine solid waste in the flexible mold support assembly is three-layered.

[0015] Preferably, the three-layer structure of the geotextile bag containing the bagged mine solid waste in the flexible formwork support component is a basalt fiber geogrid layer, an adhesive layer, and a geotextile layer. The flexible formwork support component uses mine solid waste as the filling material for the geotextile bag and combines it with the geogrid for constraint and positioning. The geotextile bag is made of polypropylene geotextile.

[0016] Preferably, the intersections of the warp and weft of the basalt fiber geogrid layer contain tiny protrusions, the adhesive layer uses a two-component polyurethane adhesive, and the bagged mine solid waste is transported by mine cars and rails in the transport roadway.

[0017] Preferably, the flexible mold support assembly contains a displacement sensor with a metal shell. The displacement sensor is connected to a displacement monitoring device via a displacement monitoring wire. The top of the bag of bagged mine solid waste in the flexible mold support assembly is designed with a rectangular filling opening of 600mm×200mm.

[0018] Preferably, the bagged mine solid waste in the flexible mold support assembly is provided with three one-way exhaust valves with a diameter of 10mm on both sides of the filling port. The bagged mine solid waste in the flexible mold support assembly is made of gangue and tailings materials, and its particle size is less than 0.5cm.

[0019] Compared with the prior art, the beneficial effects that this invention can achieve are:

[0020] 1. This invention enables rapid and synchronized advancement of roadway support and working face mining, significantly improving construction efficiency. The system, through hydraulically driven temporary support components and a retractable horizontal hydraulic rod structure, can quickly move forward and construct new support sections in close following the advancement of the coal mining face. Combined with the mine cars and conveyor belt system in the transport roadway, as well as the standardized rectangular filling port and rapid sealing process adapted to automated robots on the top of the bag, it realizes efficient operation of the entire process of bagged solid waste from transportation, filling to stacking. This dynamic tracking design avoids the problem of traditional support lagging behind mining, can timely control roof subsidence, significantly shortens the cycle operation time, and effectively ensures the rapid preservation and reuse of roadways.

[0021] 2. This invention constructs a flexible support wall with high strength and excellent integrity, ensuring the long-term stability of the support structure. The support structure uses standardized-sized bags of solid waste, which are stacked in a crisscross and interlocking manner, reinforced by metal gaskets between the bags, forming a composite structure with superior mechanical properties. In particular, the three-layer composite design of the bags is as follows: the inner layer is a basalt fiber geogrid with micro-protrusions, whose high tensile strength and low elongation provide strong skeletal constraints; the middle layer is a high-performance two-component polyurethane adhesive, forming a strong cross-linked structure; and the outer layer is a wear-resistant polypropylene geotextile. This structure effectively constrains and strengthens the filled gangue, tailings, and other solid waste materials, giving the support wall both high load-bearing capacity and good toughness.

[0022] 3. This invention establishes a real-time dynamic safety monitoring and early warning mechanism, which greatly enhances the safety of underground operations. Displacement sensors with metal shells are pre-embedded at key locations within the flexible support wall and connected to the rear monitoring device via wires. This enables continuous and real-time monitoring of the internal deformation of the support under mine pressure. This real-time feedback mechanism allows maintenance personnel to promptly grasp the stability status of the support and provide early warnings when deformation exceeds limits or abnormalities occur. This provides a valuable time window for taking reinforcement measures or evacuating personnel, thus forming a proactive safety assurance system.

[0023] 4. This invention realizes the resource utilization of solid waste in mines, achieving significant environmental and economic benefits. The system innovatively uses solid waste such as gangue and tailings generated during coal mine production as the core filling material for roadway support walls. This not only significantly reduces the high costs and land occupation problems caused by waste transportation to the surface and surface storage, but also reduces the potential pollution of solid waste to the environment from the source. At the same time, this solution reduces the dependence on traditional support materials such as cement and sand, turning waste into treasure and achieving a win-win situation for both economic and environmental benefits.

[0024] 5. This invention possesses excellent flexibility and self-adaptability, effectively adapting to complex and varied surrounding rock conditions. The support wall formed by stacking bagged solid waste is not a rigid structure, but a flexible body with a certain degree of compressibility. When the roof presses down or the surrounding rock deforms, the wall can buffer and absorb concentrated stress through its own moderate and controllable compression deformation, thereby avoiding brittle failure caused by rigid resistance. This "softness overcomes rigidity" characteristic enables it to better adapt to complex mechanical environments such as lateral roof fracture and subsidence along the goaf, exhibiting stronger geological condition adaptability and support reliability.

[0025] 6. This invention embodies a highly modular, standardized, and intelligent design philosophy, enhancing the system's scalability and maintainability. From uniformly sized bagged solid waste modules and flexibly arranged hydraulic support units to standardized filling interfaces and monitoring sensors, the entire system consists of multiple standardized modules with clearly defined functions. This design not only makes on-site construction organization flexible and convenient, and easy to adjust the support density and range according to the specific conditions of the tunnel, but also lays the foundation for future automation and intelligent upgrades (such as fully automatic filling robots and IoT-based monitoring cloud platforms). The system exhibits excellent scalability and maintainability.

[0026] 7. This invention drives the movable block to move by rotating the support screw, and then converts the movement into horizontal thrust through the hinge rod and the moving plate, so that the side blocks on both sides extend horizontally outward from the first support top plate, thereby significantly expanding the bottom support area. This operation greatly enhances the stability of the support column on the soft bottom plate, prevents sinking, and provides a solid and reliable foundation for subsequent operations. After stabilization, the first vertical hydraulic rod and the X-shaped movable bracket in the assembly quickly move to apply active support force to the exposed top plate, control its sinking, and form a safe temporary working space.

[0027] 8. This invention promotes the lifting component, which significantly improves the active adaptability and support response accuracy of the temporary support system. The component can achieve stepless, stable, and controllable adjustment of the height of the first support roof, enabling the support point to quickly and accurately conform to the contour of the roadway roof. This effectively overcomes the problems of poor initial contact and uneven distribution of support force caused by roof undulation or local subsidence in traditional support. It fundamentally enhances the immediate reliability of temporary support and its adaptability to surrounding rock conditions. At the same time, its programmable control feature provides a hardware foundation for the dynamic compensation and maintenance of temporary support force, enabling the system to automatically adjust the height compensation according to the slight deformation of the roof, maintain a constant active support force, and thus provide more stable safety protection during the critical unsupported roof transition period. Attached Figure Description

[0028] Figure 1 This is a schematic diagram illustrating the working principle of the system in this invention in a mine;

[0029] Figure 2 This invention features a flexible wall for bagged mine solid waste arranged in a crisscross pattern.

[0030] Figure 3 In this invention Figure 2 Enlarged view of point A shown;

[0031] Figure 4 This is a diagram of the bag surface structure of the bagged mine solid waste in this invention;

[0032] Figure 5 This is a layered exploded structural diagram of the bag surface of the bagged mine solid waste in this invention;

[0033] Figure 6 This is a diagram illustrating the use of mine cars to transport bagged mine solid waste in this invention.

[0034] Figure 7 This is a schematic diagram of the displacement monitoring device in this invention.

[0035] Figure 8 This is a schematic diagram illustrating the working principle of the system in different mining faces of the present invention.

[0036] Figure 9 This is a diagram showing the internal structure of the first supporting base plate in this invention;

[0037] Figure 10 This is a structural diagram of the fixed cover in this invention;

[0038] Figure 11 This is a structural diagram of the supporting rotating rod in this invention;

[0039] Figure 12 This is a structural diagram of the servo motor in this invention.

[0040] The components include: 1. Transport roadway; 2. Return air roadway; 3. First supporting roof plate; 4. X-shaped movable support; 5. Metal limiting groove; 6. First supporting base plate; 7. Horizontal hydraulic rod; 8. First vertical hydraulic rod; 9. Hydraulic metal support; 10. Bagged mine solid waste; 11. Displacement monitoring wire; 12. Bag surface of bagged mine solid waste; 13. Basalt fiber geogrid layer; 14. Small protrusions at the intersection of the warp and weft of the basalt fiber geogrid layer; 15. Adhesive layer; 16. Geotextile layer; 17. Mine car; 18. Rail; 19. Displacement monitoring device; 20. Displacement sensor; 3 0. Second support top plate; 31. Second support bottom plate; 32. Second vertical hydraulic rod; 33. Metal gasket; 40. Support screw; 41. Movable block; 42. Movable plate; 43. Hinge rod; 44. Connecting plate; 45. Motion plate; 46. L-shaped limit rod; 47. Side block; 48. Connecting rod; 49. Rotating handle; 50. Square bottom block; 60. Fixed cover; 61. Movable cover; 62. Top cover; 63. First connecting seat; 64. First arc-shaped arm; 65. Second connecting seat; 66. Second arc-shaped arm; 67. Rotating arm; 68. Support rotating rod; 70. Motor plate; 71. Servo motor. Detailed Implementation

[0041] To make the technical means, creative features, and achieved objectives and effects of this invention easier to understand, the invention is further described below with reference to specific embodiments. However, the following embodiments are merely preferred embodiments of this invention and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments described herein without creative effort are all within the protection scope of this invention. Unless otherwise specified, the experimental methods in the following embodiments are conventional methods, and the materials and reagents used in the following embodiments are commercially available unless otherwise specified.

[0042] A bagged mine solid waste system for rapid roadway side flexible formwork support in goaf retention includes a transport roadway 1 located near the lower section and a return air roadway 2 located near the upper section. Both the transport roadway 1 and the return air roadway 2 are equipped with bagged mine solid waste devices for rapid roadway side flexible formwork support. The bagged mine solid waste devices for rapid roadway side flexible formwork support include a first supporting roof plate 3. The first supporting roof plate 3 is equipped with temporary support components, which include an X-shaped movable bracket 4, a metal limiting groove 5, a first supporting base plate 6, a first vertical hydraulic rod 8, a hydraulic metal support 9, and a horizontal hydraulic rod 7.

[0043] The horizontal hydraulic rod is also equipped with a flexible mold support assembly, which includes a second support top plate 30, a second support bottom plate 31, a second vertical hydraulic rod 32, a metal gasket 33, bagged mine solid waste 10, and a displacement monitoring wire 11. The flexible mold support assembly is driven to extend by the horizontal hydraulic rod 7 and extends synchronously with the temporary support assembly as the mining face advances, thereby continuously increasing the support length of the flexible mold support assembly.

[0044] The transport roadway 1 is equipped with a conveyor belt and mine car rails 18. The bagged mine solid waste 10 in the flexible mold support assembly measures 80cm x 40cm and is arranged as follows... Figure 2 The diagram shows a crisscrossing and interlocking geotextile bag structure for the bagged mine solid waste 10 in the flexible mold support assembly. This structure consists of three layers, as shown below. Figure 4 , Figure 5 As shown. The geotextile bag structure of the bagged mine solid waste 10 in the flexible formwork support component consists of a basalt fiber geogrid layer 13, an adhesive layer 15, and a geotextile layer 16. The flexible formwork support component uses mine solid waste as the filling material for the geotextile bags, and combines it with the geogrid 13 for restraint and positioning. The geotextile bags are made of polypropylene geotextile.

[0045] The basalt fiber geogrid layer 13 should meet the following performance requirements: warp tensile strength ≥ 62.5 kN / m, weft tensile strength ≥ 61.6 kN / m, and elongation at break ≤ 2.9% (where warp and weft tensile strength represent the minimum force values ​​at which the geogrid breaks in the warp and weft directions, respectively, and elongation at break represents the ratio of the increase in length per unit length of the geogrid at break to its initial length). The intersections of the warp and weft lines of the basalt fiber geogrid layer 13 contain minute protrusions 14, which can enhance the interlocking action between the bagged mine solid waste 10.

[0046] The adhesive layer 15 uses a two-component polyurethane adhesive, formulated as follows: component A (containing 40-50 parts of polyether polyol, 15-20 parts of calcium carbonate, 1-3 parts of silane coupling agent, etc.) and component B (containing 60-70 parts of isocyanate prepolymer, 3-5 parts of nano-silica, etc.) are mixed at a mass ratio of 5:1. This mixture forms a high-strength cross-linked structure, which enhances the adhesion between the fiber geogrid layer 13 and the geotextile layer 16. The bagged mine solid waste 10 can be quickly transported from the filling point to the location requiring support via mine cars 17 using rails 18 and conveyor belts in the transport roadway 1. The flexible mold support assembly includes a displacement sensor 20 with a metal shell. The displacement sensor 20 is connected to a displacement monitoring device 19 via a displacement monitoring wire 11, enabling real-time monitoring of the stability of the flexible mold support assembly. The top of the bag 12 containing the bagged mine solid waste in the flexible mold support assembly is designed with a 600mm × 200mm rectangular filling opening, with wear-resistant nylon Velcro sewn along the edges (double-fixed with metal clips), compatible with the filling nozzle (150mm in diameter) of an automated filling robot. A single filling time is ≤30 seconds. After filling, a secondary seal is applied using a hot melt adhesive strip (50mm wide) to ensure no leakage of the filler material (such as self-bonding slag). The bagged mine solid waste 10 in the flexible mold support assembly has three 10mm diameter one-way exhaust valves (exit only, no inlet) on both sides of the filling opening. These valves expel air from the bag during filling (increasing the density to over 95%). When the pressure inside the bag exceeds 0.3MPa (in case of sudden mine pressure), automatic pressure relief is provided to prevent the bag from bursting.

[0047] The filling material for bagged mine solid waste 10 in the flexible formwork support assembly can be gangue, tailings, etc., but its particle size should be less than 0.5cm. If fly ash or other materials are used, 30% by mass of silicate cement slurry can be added for reinforcement. The flexible formwork support device can be flexibly arranged according to the size of the mining face area, such as... Figure 8 As shown.

[0048] Example 1

[0049] A bagged mine solid waste device for flexible formwork support along goaf roadways, the support method and steps are as follows:

[0050] Before construction, geotextile bags are prefabricated outside the well. The unit area mass of the geotextile bags is 80g / m². The mine solid waste is filled into the geotextile bags, with a filling rate of 90%. A two-component polyurethane adhesive is used to make the adhesive layer. The formula is as follows: component A (containing 40-50 parts of polyether polyol, 15-20 parts of calcium carbonate, 1-3 parts of silane coupling agent, etc.) and component B (containing 60-70 parts of isocyanate prepolymer, 3-5 parts of nano silica, etc.) are mixed at a mass ratio of 5:1. Basalt geogrid is then cut according to the height and width of the geotextile bags and wrapped with basalt fiber geogrid. The joints of the geogrids are connected with plastic strips, ensuring that the geogrid is taut during connection. Using mining cars, geotextile bags wrapped with geogrid are transported to the vicinity of the working face. As mining progresses, a base plate is installed behind the end support of the working face, and hydraulic props are used in conjunction with the hinged roof plate as temporary support. A hydraulic prop is placed every 1.2 meters to prevent roof collapse. The geotextile bags are stacked on the base plate in a crisscross pattern until they contact the roof. The geotextile bags are 80cm x 40cm in size. Displacement monitoring devices are used to check whether the deformation of the flexible support exceeds the limit. After the roof stabilizes, the temporary hydraulic props are removed. As mining progresses, steps one through four are repeated until the entire roadway is mined, completing the flexible support work along the side of the goaf for the geotextile bagged mine solid waste.

[0051] Example 2

[0052] A bagged mine solid waste device for flexible formwork support along goaf roadways, the support method and steps are as follows:

[0053] A coal mine covers an area of ​​25.3862 km². The total length of the mining area is 4.37 km, the width is 3.6 km, and the area is 15.732 km². The elevation range of the mining area is -100 m to -120 m. There are no important buildings on the surface, no need to leave protective coal pillars, no water bodies on the surface, and no small wells on the surface, which have no impact on the working face. Ordinary houses on the surface within the mining face area have been renovated into shantytowns and are currently uninhabited. No surface cracks or subsidence have been found on the surface. In the working face along the goaf, the No. 85 coal seam is mainly mined using the fully mechanized top coal caving method. The No. 85 coal seam has a primary structure and is found in a layered state. The coal and rock types are clearly defined, presenting large blocks with well-defined edges. No wrinkled or mirror-like surfaces are observed. The coal seam is hard when touched, and its structure is stable, showing no change from the upper to the lower roadway and from left to right. The average thickness of this coal seam is 8.36m, which also contains fine sandstone with an average thickness of 0.7m, siltstone with an average thickness of 0.4m, the No. 85 coal seam itself with an average thickness of 0.71m, interbedded fine and silty sandstone with a thickness of 4.75m, fine sandstone with a thickness of 1.0m, and siltstone with a thickness of 0.8m. The dip angle of the coal seam is between 9 and 22°, and the average burial depth is 116m.

[0054] Before construction, geotextile bags should be prepared outside the well in advance, such as... Figure 6 As shown in Figure 10, the unit area mass of the geotextile bag is 80 g / m². Mine solid waste is filled into the geotextile bags, with a filling rate of 90%. A two-component polyurethane adhesive is used, with component A (containing 40-50 parts polyether polyol, 15-20 parts calcium carbonate, 1-3 parts silane coupling agent, etc.) and component B (containing 60-70 parts isocyanate prepolymer, 3-5 parts nano-silica, etc.) mixed at a mass ratio of 5:1 to create the adhesive layer. Basalt geogrid is cut according to the height and width of the geotextile bag and wrapped with basalt fiber geogrid. Plastic strips are used to connect the geogrid joints, ensuring the geogrid is taut during connection. The geotextile bags wrapped with geogrid are transported to the vicinity of the working face using mine cars. As the working face advances, a base plate is placed behind the end support of the working face, and the top plate is hinged using hydraulic supports and X-shaped movable supports. Figure 1 As shown in Figure 4, as temporary support, a hydraulic prop is installed every 1.2 meters, such as... Figure 2 As shown in Figure 8, measures are taken to prevent roof collapse accidents. The base slab, as... Figure 2 As shown in Figure 6, the upper part adopts a crisscross stacking method, such as... Figure 2 As shown in Figure A, the flexible wall of bagged mine solid waste is stacked until it contacts the roof. The dimensions of the geotextile bags are 80cm x 40cm. A displacement monitoring device is used to check whether the deformation of the flexible support exceeds the standard. After the roof stabilizes, the temporary hydraulic supports are removed. As the working face advances, steps one through four are repeated, and this cycle continues until the roadway is completely mined, thus completing the flexible support work along the side of the bagged mine solid waste access roadway.

[0055] Example 3

[0056] A bagged mine solid waste system for flexible formwork support along goaf-retention roadways, see reference. Figure 8 and Figure 9 The first support top plate 3 is provided with an expansion assembly inside. The expansion assembly includes a support screw 40, a movable block 41, a hinge rod 43 and a side block 47. The support screw 40 is movably connected to the center of the first support top plate 3. The movable block 41 is threaded through the support screw 40. Movable plates 42 are fixedly installed on both sides of the movable block 41. L-shaped limiting rods 46 are fixedly installed around the inside of the first support top plate 3. A moving plate 45 is movably connected between the L-shaped limiting rods. The moving plate 45 is horizontal with the support screw 40.

[0057] Both ends of the movable plate 42 are movably connected to the moving plate 45 by hinge rods 43. The moving plate 45 has connecting rods 48 fixedly installed at both ends on the side away from the support screw 40. The connecting rods 48 extend through to the outside of the first support top plate 3 at the end away from the support screw 40. Side blocks 47 are fixedly installed between the top ends of the connecting rods 48.

[0058] One end of the support screw 40 extends through to the outside of the first support top plate 3, and a rotating handle 49 is fixedly installed at the top of the support screw 40. A connecting plate 44 is fixedly installed at the end of the moving plate 45 away from the rotating handle 49, and the connecting plate 44 extends through to the outside of the first support top plate 3. A square base block 50 is fixedly installed between the tops of the connecting plates 44.

[0059] This bagged mine solid waste system, designed for rapid roadway support along the goaf, is a continuous process integrating dynamic temporary support, flexible wall construction, real-time safety monitoring, and self-adaptive stabilization. Its core lies in simultaneously constructing a flexible continuous support wall composed of bagged mine solid waste on the goaf side of the roadway as mining progresses, maintaining roadway stability and enabling the resource utilization of mine solid waste.

[0060] The entire system begins with the advancement of the working face. As the coal mining machine cuts forward through the coal face, the roof behind it is gradually exposed and may sink. At this point, the temporary support components located in the transport roadway and return air roadway are immediately activated. The operator can first operate the expansion component at its bottom: by rotating the support screw 40, the movable block 41 is driven to move, and then the movement is converted into horizontal thrust through the hinged rod 43 and the moving plate 45, causing the side blocks 47 on both sides to extend horizontally outward from the first support roof 3, thereby significantly expanding the bottom support area. This operation greatly enhances the stability of the support on the soft floor, prevents sinking, and provides a solid and reliable foundation for subsequent operations. After stabilization, the first vertical hydraulic rod 8 and the X-shaped movable support 4 in the component quickly move to apply active support force to the exposed roof, control its sinking, and form a safe temporary working space.

[0061] With the temporary roof effectively controlled, the flexible formwork support assembly begins constructing the permanent roadway side support. This process is synchronized with the mining face. Driven by the hydraulic system, the horizontal hydraulic rod 7 pushes the overall frame of the flexible formwork support assembly towards the temporarily supported goaf side. Next, mine solid waste (gangue and tailings, particle size less than 0.5cm), transported via mine cars 17 and rails 18 in the roadway, is filled into specially designed geotextile bags. These geotextile bags employ a three-layer composite structure: an inner layer of basalt fiber geogrid 13 with micro-protrusions to enhance adhesion to the material; a middle layer of two-component polyurethane adhesive 15; and an outer layer of wear-resistant polypropylene geotextile 16. The bags are uniformly sized (80cm × 40cm) and equipped with a filling port and a one-way vent valve at the top. Workers stacked and compacted the filled bags layer by layer within the flexible space formed by the second supporting top plate 30 and the second supporting bottom plate 31 in a crisscrossing and interlocking manner, quickly constructing a dense, flexible wall. This wall utilizes the constraint of geogrids and the friction between the bags to form a whole with high compressive and deformation resistance.

[0062] To ensure the long-term safety of the support structure, an intelligent monitoring mechanism is integrated into the system. When stacking bagged solid waste, displacement sensors 20 with metal shells are pre-installed at key locations. These sensors are connected to a stable displacement monitoring device 19 at the rear via displacement monitoring wires 11, which can monitor the internal deformation and displacement of the flexible wall under the continuous pressure of the roof slab in real time and continuously. Once the data is abnormal, an early warning can be issued in time to guide reinforcement measures.

[0063] Example 4

[0064] A bagged mine solid waste system for flexible formwork support along goaf-retention roadways, see reference. Figure 10 , Figure 11 and Figure 12 The top of the first support base plate 6 is provided with a push lifting assembly, which includes a fixed cover 60, a movable cover 61 and a top cover 62. Fixed covers 60 are fixedly installed at both ends of the top of the first support base plate 6. A first connecting seat 63 is fixedly installed at the center of the bottom of each fixed cover 60. A first arc-shaped arm 64 is movably connected to the first connecting seat 63. The movable cover 61 is movable on the outer periphery of the top of the fixed cover 60. A support rotating rod 68 is movably connected between the movable covers 61. Rotating arms 67 are fixedly installed at both ends of the support rotating rod 68, and the rotating arms 67 are movable inside the movable cover 61.

[0065] A top cover 62 is fixedly installed at the bottom of the first support top plate, and the top cover 62 is movable around the outer periphery of the movable cover 61. A second connecting seat 65 is fixedly installed at the center of the inner top of the top cover 62. A second arc-shaped arm 66 is movably connected to the second connecting seat 65. The first arc-shaped arm 64 and the second arc-shaped arm 66 are respectively movably connected to the two ends of the rotating arm 67.

[0066] The movable cover 61 has a motor plate 70 fixedly installed on the inner side near the transport tunnel. A servo motor 71 is fixedly installed on the top of the motor plate 70, and the output end of the servo motor 71 is fixedly installed on the top of the support rod 68.

[0067] The lifting assembly is integrated between the first support base plate and the first support top plate. Its core function is to achieve precise and controllable adjustment of the height of the first support top plate, so as to actively adapt to the undulation of the tunnel roof and optimize the initial state of the temporary support. Its working principle is based on a linkage transmission system driven by a servo motor 71. When it is necessary to raise the first support top plate, the servo motor 71 starts and drives the support rotating rod 68 fixed at its output end to rotate. The rotation of the support rotating rod 68 is directly transmitted to the rotating arms 67 fixed at both ends, so that the rotating arms 67 rotate synchronously. The rotation of the rotating arms 67 then drives the first arc-shaped arm 64 and the second arc-shaped arm 66, which are respectively hinged to their ends, to swing in a coordinated manner. The middle part of the first arc-shaped arm 64 is hinged to the first connecting seat 63 fixed on the first support base plate. Its swing transmits power to the connection point with the inside of the movable cover 61, thereby pushing the movable cover 61 to extend smoothly upward from the fixed cover 60 at the bottom, completing the first... The first support plate is raised in two stages. Simultaneously, the middle of the second arc-shaped arm 66 is hinged to the second connecting seat 65, which is fixed inside the top cover 62 below the first support plate. Its swinging motion pushes the top cover 62 to extend further upward on the basis of the already raised movable cover 61, driving the first support plate to achieve a second stage of lifting. Finally, it makes it closely contact and press against the roadway roof. When it is necessary to lower the height, the servo motor 71 reverses. Through the reverse transmission of the above-mentioned linkage system, it sequentially drives the top cover 62 to descend and retract into the movable cover 61. Then, the movable cover 61 descends and retracts into the fixed cover 60, so that the entire mechanism returns to a compact state. This design, through the force amplification and guiding effect of the mechanical linkage, transforms the rotational motion of the motor into a smooth and controllable linear lifting motion. It not only realizes the stepless precision adjustment of the support height and enhances the active adaptability of the support system to the roadway roof conditions, but also lays the hardware foundation for subsequent possible automatic height adjustment intelligent control based on pressure or displacement feedback.

[0068] The push-lifting assembly based on the servo motor 71 and linkage transmission principle significantly improves the active adaptability and support response accuracy of the temporary support system. This assembly can achieve stepless, stable, and controllable adjustment of the height of the first support roof, enabling the support point to quickly and accurately conform to the contour of the roadway roof. It effectively overcomes the problems of poor initial contact and uneven distribution of support force caused by roof undulation or local subsidence in traditional support, fundamentally enhancing the immediate reliability of temporary support and its adaptability to surrounding rock conditions. At the same time, its programmable control feature provides a hardware foundation for the dynamic compensation and maintenance of temporary support force, enabling the system to automatically adjust the height compensation according to slight roof deformation, maintain a constant active support force, and thus provide more stable safety protection during the critical unsupported roof transition period.

[0069] Working principle:

[0070] The first step is to make geotextile bags from polypropylene geotextile fabric. The manufacturing process is as follows: cut a piece of geotextile fabric with a length and width of 144cm×28cm, fold it in half along the length, fold it inward 2cm along the edge, and then fix it with a stapler. Then sew it with a hand-held sewing machine. Fold the bottom layer inward 2cm along the edge in the same way and sew it with a hand-held edge sealing machine. After filling the geotextile bag with mine solid waste, repeat the same operation on the top layer and seal the edges to make a geotextile bag with a size of 80cm×40cm without filling. The adhesive layer can be cut out in the same way.

[0071] The second step involves filling the geotextile bags with the mine solid waste using a filling device, while simultaneously vibrating the bags until they are almost completely filled (this is defined as 100% filling). After sewing the filling opening, a three-dimensional bag containing the mine solid waste is formed. Considering the actual conditions of the working face along the goaf in the coal mine, the economic cost of the geotextile bags, and the labor intensity during construction, the size and weight of the bagged mine solid waste should not be too flat, and the filling degree of the geotextile bags should not be too low. Therefore, a filling degree of 90% is selected for the bagged mine solid waste, and the unit area mass of the geotextile bag is taken as 80 g / m².

[0072] The third step involves cutting basalt geogrids according to the height and width of the geotextile bags, wrapping them with basalt fiber geogrids, and connecting the geogrid joints with plastic strips, ensuring the geogrids are taut during connection. The finished bagged mine solid waste is then neatly stacked in mine cars and quickly transported to the goaf roadway via mine car rails and conveyor belts.

[0073] The fourth step involves placing a base plate behind the working face as mining progresses. Hydraulic props, in conjunction with X-shaped movable supports, are used to hinge the roof plate as temporary support. A hydraulic prop is placed every 1.2 meters to prevent roof collapse. Flexible walls made of bagged mine solid waste are stacked on the base plate in a crisscross pattern until they contact the roof plate, and displacement sensors are placed within them for monitoring.

[0074] Fifth, using a displacement monitoring device, check whether the deformation of the flexible formwork support exceeds the standard. After the roof stabilizes, remove the temporary hydraulic supports. Simultaneously, as the working face continues to advance, repeat steps one through four until the tunnel is completely mined.

[0075] The above-mentioned geogrid is a basalt fiber geogrid, and its performance indicators should meet the following requirements: warp tensile strength ≥ 62.5 kN / m, weft tensile strength ≥ 61.6 kN / m, and elongation at break ≤ 2.9% (where warp and weft tensile strength represent the minimum force values ​​of the geogrid when it is broken in the warp and weft directions, respectively, and elongation at break represents the ratio of the increase in length of the geogrid per unit length when it is stretched at break to the initial length).

[0076] The aforementioned mine solid waste is generally in a loose state and is prone to tensile failure when subjected to external loads, while geotextiles have high tensile strength. When geotextiles are made into geotextile bags and filled with mine solid waste, the friction between the filled mine solid waste and the geotextile effectively diffuses the stress in the mine solid waste soil, limits and increases the modulus of the mine solid waste, and transmits tensile stress through the geotextile, limiting the lateral deformation of the mine solid waste between its upper and lower sections. This improves the tensile and shear strength of the mine solid waste soil and enhances its stability.

[0077] The aforementioned geotextile bags themselves possess high load-bearing capacity, and the basalt fiber geogrid exhibits high tensile strength and low elongation, further enhancing the load-bearing and support capabilities of the geotextile bag stacks. Furthermore, the intersections of the warp and weft threads of the basalt fiber geogrid contain minute protrusions, which can further strengthen the interlocking action between the bagged mine solid waste.

[0078] The aforementioned stack of geotextile bags initially bears the vertical load. As the solid waste inside the bags is gradually compacted, the contact between the geotextile bags and the geogrid becomes tighter, and the geotextile bags undergo vertical and axial deformation. When the bags are in close contact with the geogrid, the geogrid restricts the lateral deformation of the geotextile bags, at which point the geogrid plays a significant reinforcing role.

[0079] The aforementioned mine solid waste particles can be made from materials such as gangue and tailings, but their particle size should be less than 0.5 cm. If materials such as fly ash are used, 30% by mass of silicate cement slurry can be added for reinforcement.

[0080] The stacked flexible wall employs alternating longitudinal and transverse layers. This arrangement not only increases the friction between each layer of geotextile bags but also allows the interlocking stacking of upper and lower layers to form a unified flexible wall. Once the wall stabilizes, the flexibility of the geotextile bags allows the gaps between them to be filled by the compression and deformation of the upper and lower layers, creating a more stable force chain contact structure and further enhancing the overall stability of the wall. Furthermore, the intersections of the warp and weft threads of the basalt fiber geogrid layer contain tiny protrusions, which enhance the interlocking effect between the bagged mine solid waste.

[0081] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention.

Claims

1. A bagged mine solid waste system for flexible formwork support along a goaf-retention roadway, comprising a transport roadway (1) located near the lower section and a return airway (2) located near the upper section, characterized in that, Both the transport roadway (1) and the return air roadway (2) are equipped with a bagged mine solid waste device with rapid roadway side flexible formwork support. The bagged mine solid waste device with rapid roadway side flexible formwork support includes a first support top plate (3). A temporary support assembly is provided on the first support top plate (3). The temporary support assembly includes an X-shaped movable bracket (4), a metal limiting groove (5), a first support bottom plate (6), a first vertical hydraulic rod (8), a hydraulic metal support (9), and a horizontal hydraulic rod (7). The horizontal hydraulic rod is also equipped with a flexible mold support assembly, which includes a second support top plate (30), a second support bottom plate (31), a second vertical hydraulic rod (32), a metal gasket (33), bagged mine solid waste (10), and a displacement monitoring wire (11).

2. A bagged mine solid waste system for rapid roadway side flexible formwork support along the goaf, as described in claim 1, is characterized in that... The top of the first support base plate (6) is provided with a push lifting assembly. The push lifting assembly includes a fixed cover (60), a movable cover (61) and a top cover (62). Fixed covers (60) are fixedly installed at both ends of the top of the first support base plate (6). A first connecting seat (63) is fixedly installed at the center of the bottom of the fixed cover (60). A first arc arm (64) is movably connected to the first connecting seat (63). The movable cover (61) is movable on the outer periphery of the top of the fixed cover (60). A support rotating rod (68) is movably connected between the movable covers (61). Rotating arms (67) are fixedly installed at both ends of the support rotating rod (68), and the rotating arms (67) are movable inside the movable cover (61). A top cover (62) is fixedly installed at the bottom of the first support top plate (3), and the top cover (62) is movable around the outer periphery of the movable cover (61). A second connecting seat (65) is fixedly installed at the center of the inner top of the top cover (62). A second arc arm (66) is movably connected to the second connecting seat (65). The first arc arm (64) and the second arc arm (66) are respectively movably connected to the two ends of the rotating arm (67). The movable cover (61) has a motor plate (70) fixedly installed on the inner side near the transport tunnel. A servo motor (71) is fixedly installed on the top of the motor plate (70), and the output end of the servo motor (71) is fixedly installed on the top of the support rod (68).

3. A bagged mine solid waste system for rapid roadway side flexible formwork support along the goaf, as described in claim 1, is characterized in that... The first support top plate (3) is provided with an expansion assembly inside. The expansion assembly includes a support screw (40), a movable block (41), a hinge rod (43), and a side block (47). The support screw (40) is movably connected to the center of the first support top plate (3). The movable block (41) is threaded through the support screw (40). Movable plates (42) are fixedly installed on both sides of the movable block (41). L-shaped limiting rods (46) are fixedly installed around the inside of the first support top plate (3). A moving plate (45) is movably connected between the L-shaped limiting rods. The moving plate (45) and the support screw (40) are in a horizontal state. The two ends of the movable plate (42) are movably connected to the moving plate (45) by hinge rods (43) through hinges. The moving plate (45) has connecting rods (48) fixedly installed at both ends on the side away from the support screw (40), and the connecting rods (48) extend through to the outside of the first support top plate (3) at the end away from the support screw (40). Side blocks (47) are fixedly installed between the top ends of the connecting rods (48). One end of the support screw (40) extends through to the outside of the first support top plate (3), and a rotating handle (49) is fixedly installed at the top of the support screw (40). A connecting plate (44) is fixedly installed at the end of the moving plate (45) away from the rotating handle (49), and the connecting plate (44) extends through to the outside of the first support top plate (3). A square base block (50) is fixedly installed between the tops of the connecting plates (44).

4. A bagged mine solid waste system for rapid roadway side flexible formwork support along the goaf, as described in claim 1, is characterized in that... The flexible formwork support assembly is extended by a horizontal hydraulic rod (7), and extends synchronously with the temporary support assembly as the mining face advances, thereby continuously increasing the support length of the flexible formwork support assembly.

5. A bagged mine solid waste system for rapid roadway side flexible formwork support along the goaf, as described in claim 1, is characterized in that... The transport roadway (1) is equipped with a conveyor belt and mine car rails (18).

6. A bagged mine solid waste system for rapid roadway side flexible formwork support along the goaf, as described in claim 1, is characterized in that... The bagged mine solid waste (10) in the flexible mold support assembly has a length × width of 80cm × 40cm and adopts a crisscrossing and interlocking method. The geotextile bag structure of the bagged mine solid waste (10) in the flexible mold support assembly is three layers.

7. A bagged mine solid waste system for rapid roadway side flexible formwork support along the goaf, as described in claim 6, is characterized in that... The three-layer structure of the geotextile bag of the bagged mine solid waste (10) in the flexible formwork support component is a basalt fiber geogrid layer (13), an adhesive layer (15), and a geotextile layer (16). The flexible formwork support component uses mine solid waste as the filling material of the geotextile bag and combines it with the geogrid (13) for constraint and limitation. The geotextile bag is made of polypropylene geotextile.

8. A bagged mine solid waste system for rapid roadway side flexible formwork support along the goaf, as described in claim 7, is characterized in that... The basalt fiber geogrid layer (13) contains tiny protrusions (14) at the intersection of the warp and weft lines. The adhesive layer (15) is made of two-component polyurethane adhesive. The bagged mine solid waste (10) is transported by mine cars (17) and rails (18) in the transport roadway (1).

9. A bagged mine solid waste system for rapid roadway side flexible formwork support along the goaf, as described in claim 8, is characterized in that... The flexible mold support assembly contains a displacement sensor (20) with a metal shell. The displacement sensor (20) is connected to the displacement monitoring device (19) through a displacement monitoring wire (11). The top of the bag surface (12) of the bagged mine solid waste in the flexible mold support assembly is designed with a rectangular filling opening of 600mm×200mm.

10. A bagged mine solid waste system for rapid roadway side flexible formwork support along the goaf, as described in claim 9, is characterized in that... The bagged mine solid waste (10) in the flexible mold support assembly is provided with three one-way exhaust valves with a diameter of 10mm on both sides of the filling port. The bagged mine solid waste (10) in the flexible mold support assembly is made of gangue and tailings materials, and its particle size is less than 0.5cm.

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