Automated Gate Entry Support for Underground Mining
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Solution Overview
Problem
Conventional gate entry support systems in underground full extraction mining are costly, labor-intensive, and often ineffective in maintaining safe access due to their passive nature and manual installation, leading to frequent replacements and safety concerns from roof and floor failures.
Innovation Solution
An automated system for gate entry support that includes a sensor, drive unit, communication module, and controller to gather data, determine conditions, and autonomously advance or halt operations, using extension members and hydraulic cylinders to actively support the mine roof and floor, allowing for remote monitoring and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional passive support systems are installed manually throughout gate entries, then roof and floor support is provided, but labor costs and installation time increase significantly
Solution Approach 1:
The gate entry support system is designed to be self-installing through the drive unit that automatically advances the support along the gate entry without requiring manual installation by workers. The system monitors its own position and condition through sensors and autonomously adjusts its support function.
Solution Approach 2:
Manual mechanical installation is replaced with an automated electromechanical system comprising a drive unit with motors, sensors for monitoring position and condition, and a controller that coordinates advancement and support activation. This substitution eliminates manual labor while maintaining support reliability.
2Reliability
If conventional support materials are transported from surface to gate entry, then support structures are provided, but material transportation costs reach up to $1,000 per foot
Solution Approach 1:
The support system is extracted from the conventional approach of transporting extensive materials from the surface. Instead, a compact automated support unit is deployed that generates its support function locally without requiring continuous material supply chains from the surface, thereby eliminating transportation costs.
Solution Approach 2:
The system changes the fundamental parameters of support provision from material-intensive conventional methods to a compact automated unit that uses localized power and control systems. This parameter change transforms the support system from a material-dependent structure to a self-contained automated device.
3Strength
If passive support systems are used, then roof and floor support is provided until failure, but the systems must be frequently replaced due to failure
Solution Approach 1:
The support system incorporates sensors that continuously monitor the condition of the gate entry and the status of the support structure. This feedback is transmitted to a controller that can detect signs of impending failure and trigger proactive replacement or adjustment before actual failure occurs, thereby extending the effective lifespan of the support system.
Solution Approach 2:
The system performs preliminary monitoring and assessment of support conditions through integrated sensors. By detecting early signs of degradation or overload, the system enables preliminary actions such as adjusting support force or scheduling replacement before catastrophic failure occurs, thus extending operational duration.
4Ease of manufacture
If manual installation of support systems is performed, then support structures are deployed, but worker safety is compromised due to constant exposure to roof failure risks
Solution Approach 1:
The support system performs self-installation through its integrated drive unit that autonomously advances along the gate entry and deploys support structures without requiring workers to physically install each component. This eliminates worker exposure to roof failure risks during the installation process while maintaining ease of deployment.
Solution Approach 2:
Manual mechanical installation operations are replaced with an automated electromechanical installation system. The drive unit with integrated sensors and controllers performs all installation tasks autonomously, substituting human workers with automated machinery that is not subject to safety risks from roof failures during installation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system reduces labor and material costs, enhances safety by actively supporting the mine structure, and increases efficiency through autonomous operation and higher load capacity, minimizing the need for frequent replacements and ensuring continuous access during mining operations.
Implementation Method 1
The extension member may include one or more of a hydraulic cylinder and a hydraulic support member
Data Source
AI summary
An apparatus, system, and method for automated support of a gate entry for underground full extraction mining that includes gathering entry data for a condition of a gate entry by way of a gate entry support. The method also includes determining, by way of the gate entry support, the condition of the gate entry, advancing the gate entry support in response to determining that the condition satisfies an entry condition threshold. The method may also signal a halt condition for a production cycle, if the condition fails to satisfy the entry condition threshold.