Composite Support Structure for Deep Coal Mine Roadways
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Solution Overview
Problem
Conventional underground mining support structures, such as I-steel and anchor mesh shotcrete, are inadequate for deep coal mines, leading to instability, frequent repairs, and increased labor intensity due to separate tunneling and support processes, resulting in slow construction and high costs.
Innovation Solution
A composite support structure comprising arc plate rings and concrete fill steel tube supports, combined with an automated construction system that includes a tunneling machine, anchor rod construction apparatus, and steel pipe construction apparatus, allowing for synchronized and mechanized construction of anchor rods, arc plates, and steel pipes to enhance support strength and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional support structures (I-steel, U-shaped steel, anchor mesh shotcrete) are used in deep coal mines, then the structure is simple and easy to install, but the bearing capability is insufficient and stability decreases under deep high stress
Solution Approach 1:
The patent combines multiple support elements (arc plate rings, concrete fill steel tube supports, and anchor rods) into a composite support structure. The arc plate ring provides circumferential support, the concrete fill steel tube support provides axial bearing capacity, and the anchor rods provide rock anchoring, creating a synergistic system that achieves high bearing capability through the integration of different support mechanisms.
Solution Approach 2:
The support structure uses composite materials including steel tubes filled with concrete, arc plates made of high-strength steel, and anchor rods with grouting material. These composite material combinations leverage the complementary properties of different materials (steel's tensile strength, concrete's compressive strength) to achieve superior overall performance under deep high stress conditions.
2Productivity
If separate tunneling and support processes are used with conventional methods, then each process can be performed with simple equipment, but the construction speed is slow and labor intensity is high
Solution Approach 1:
The patent integrates the tunneling machine, anchor rod construction apparatus, and steel pipe construction apparatus into a single synchronized system. The tunneling machine excavates while the support apparatus simultaneously constructs anchor rods and installs steel pipe supports, merging previously separate sequential operations into a concurrent integrated process that dramatically increases construction speed.
Solution Approach 2:
The support apparatus is positioned and prepared in advance during the tunneling process. Anchor rods are pre-drilled and installed while the tunneling machine is still advancing, and steel pipe supports are pre-positioned and ready for immediate installation, eliminating waiting time between excavation and support construction.
3Reliability
If conventional support structures are used in deep high stress roadways, then the initial installation is simple, but large deformations occur and frequent repairs are needed
Solution Approach 1:
The composite support structure merges arc plate rings that resist circumferential pressure, concrete fill steel tube supports that resist axial compression, and anchor rods that provide rock anchoring. This multi-mechanism combination creates a redundant and robust support system that maintains reliability under deep high stress conditions where single-mechanism supports fail.
Solution Approach 2:
The support structure applies different support mechanisms to different locations and stress conditions: arc plate rings address circumferential stress distribution, concrete fill steel tube supports address axial compression zones, and anchor rods address rock anchoring requirements. Each component is optimized for its specific local function, achieving overall high reliability.
Data Source
AI summary
A composite support structure, a construction system, and a method, the composite support structure includes a plurality of arc plate rings that are longitudinally arranged along a roadway. A concrete fill steel tube support is arranged on an inner side or an outer side of each arc plate ring. The arc plate ring is formed by splicing a plurality of arc plates. Each concrete fill steel tube support is formed by splicing a plurality of steel pipe sections. The arc plate rings and the concrete fill steel tube supports are capable of jointly supporting walls of the roadway. The support structure has high bearing capability, high construction efficiency of a construction system, and low labor intensity.