Intrinsically Safe Camera Network for Longwall Face Support
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Solution Overview
Problem
Existing longwall face support systems in underground mining lack an intrinsically safe camera design suitable for underground use, with heavy cameras and unconventional data transmission methods that are not efficiently integrated into the underground data transmission system, leading to inefficiencies and safety concerns.
Innovation Solution
The development of an intrinsically safe camera system with a simple sheet metal housing, a local wireless network accessible via each camera's antenna, and redundant data transmission capabilities, allowing for both wired and wireless data transfer, reducing hardware requirements and ensuring fast data transfer between the longwall control device and shield control devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a camera is used for distance measurement instead of ultrasonic transmitter, then measurement precision is improved, but the camera becomes too heavy for practical operation
Solution Approach 1:
The patent uses camera images to create a digital representation of the longwall face geometry. Instead of using heavy specialized sensors, the system captures optical information and processes it through image recognition algorithms to derive distance and positional data, effectively copying the measurement function from physical sensors to visual processing.
Solution Approach 2:
The patent replaces mechanical/physical measurement systems (ultrasonic transmitters, heavy cameras) with an optical system combined with computational image processing. The measurement function is transferred from physical sensor-based systems to a lightweight camera system with software-based distance calculation through perspective analysis.
2Ease of operation
If wireless data transmission is implemented for camera data, then ease of operation is improved, but reliability of data transmission deteriorates due to unpredictability of radio communication underground
Solution Approach 1:
The patent implements different transmission qualities for different data types. Critical control commands and emergency signals use reliable wired transmission through the control bus, while image data and non-critical information use wireless transmission. This local differentiation of transmission quality optimizes both ease of operation and reliability where needed.
Solution Approach 2:
The system prepares for potential wireless transmission failures by having fallback wired transmission paths ready through the control bus. The dual-path architecture cushions against wireless reliability issues by providing predetermined alternative routes for critical data transmission.
3Extent of automation
If cameras are integrated into the control system for automated operation, then extent of automation is improved, but device complexity increases
Solution Approach 1:
The patent makes the existing control system and camera system perform multiple functions. The cameras serve not only for distance measurement but also for monitoring, safety detection, and operational recording. The control system processes both traditional sensor data and image data through unified algorithms, reducing the need for separate dedicated systems.
Solution Approach 2:
The patent merges the camera system with the existing control bus and processing units. Instead of creating a separate automated operation system, the cameras are integrated into the existing control architecture, sharing processors, communication channels, and power supplies, thereby reducing overall system complexity.
4Object-affected harmful factors
If intrinsically safe camera design is implemented, then safety is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent creates an intrinsically safe environment by designing the camera electronics to operate at low power levels that cannot cause ignition in potentially explosive underground atmospheres. The electronic components are rated for intrinsically safe operation, effectively creating a safe operational envelope that prevents harmful effects regardless of manufacturing variations within specified tolerances.
Data Source
AI summary
The invention relates to the longwall face support of an underground mine having supports (plates 1-18), which longwall face support comprises camera housings (35) each having two cameras (36), which record a monitoring area of the face having a plurality of plates in the longitudinal direction of the gallery and the most complete registration possible of the cross section of the gallery. The cameras in a monitoring area are assigned to a common power supply unit (48) for the power supply and are equipped with intrinsically safe electronics. The electronics have a radio device for high-frequency data transfer (transmission and reception) together with antenna 39 (W-LAN antenna) for the wire-free connection to the local camera network (Wireless Local Area Network). Each camera and each camera housing is assigned a camera code and an address code, which is added to the identification data. Each radio device is configured such that data marked with an extrinsic camera code and data and signals marked with an extrinsic address code is emitted to be transmitted following reception.