Vehicle-Supported Conveyor Roller Assembly Installation System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The installation of heavy mine belt roller assemblies in underground mining is challenging due to safety issues and production inefficiencies, requiring multiple workers and causing back injuries, and the limited space in coal mines complicates the handling and precise positioning of these heavy components.
Innovation Solution
A vehicle-supported lifting system with a manipulable crane that can extend, retract, rotate, and precisely position heavy mining conveyor belt items, eliminating the need for manual lifting and manipulation, and allowing for the replacement of conveyor belts without stopping the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual lifting and manipulation methods are used for heavy roller assemblies, then installation can be performed with simple equipment, but worker safety deteriorates and back injuries occur due to the heavy weight (over 300 lbs) requiring four or more workers
Solution Approach 1:
A mechanical lifting system acts as an intermediary between the heavy roller assemblies and the workers, transferring the lifting function from human workers to a dedicated mechanical device. The system includes a lifting device with a base, vertical mast, and horizontal boom that can lift and position roller assemblies without direct worker contact with the heavy loads.
Solution Approach 2:
The patent replaces the manual mechanical lifting system (workers using their bodies as lifting mechanisms) with a powered mechanical lifting system. The system uses a hydraulic or electric-powered boom and mast assembly to provide the lifting force, substituting human physical effort with automated mechanical power.
2Productivity
If multiple workers are used to lift and manipulate heavy roller assemblies, then installation can be accomplished with simple equipment, but production efficiency deteriorates due to extended installation time and considerable production loss
Solution Approach 1:
The lifting system is designed to perform the entire lifting and positioning operation autonomously without requiring multiple workers to manually coordinate their efforts. The powered boom and mast assembly automatically controls the lifting, positioning, and placement of roller assemblies, making the system self-sufficient for the installation task.
Solution Approach 2:
The system incorporates movable and adjustable components including a telescopic boom, rotating mast, and adjustable lifting points that can dynamically adapt to different roller assembly sizes and installation positions. This dynamic capability allows rapid reconfiguration for different installation scenarios without requiring complete system changes.
3Reliability
If large equipment is used to lift and position heavy roller assemblies, then worker safety improves by eliminating manual lifting, but the equipment cannot fit into the shaft due to limited vertical room to the mine roof
Solution Approach 1:
The lifting system employs a nested structure where the boom can be retracted into the mast, and the mast can be lowered into the base when not in use. This nesting capability allows the equipment to occupy minimal vertical space during storage and transport while providing full lifting capability when deployed, enabling it to fit within the constrained mine shaft environment.
Solution Approach 2:
The system uses dynamic, adjustable components including a telescopic mast and collapsible boom that can change their dimensions based on operational requirements. When retracted, the equipment profile is minimized to fit within the shaft clearance, while during operation, the components extend to provide the necessary lifting height and reach.
4Reliability
If the tunnel width is limited to 20 feet by law with belt lines installed on the center line, then safety regulations are met, but lateral space for mechanical installation deteriorates to only about 10 feet
Solution Approach 1:
The lifting system is designed to operate primarily in the vertical dimension rather than requiring extensive lateral space. The vertical mast and boom assembly can lift and position roller assemblies by moving upward and outward from a compact base position, utilizing the vertical clearance in the shaft rather than requiring broad lateral workspace.
Solution Approach 2:
The system concentrates its operational capability in a localized area around the base and mast, providing precise positioning control in the immediate vicinity of the installation point. This localized operation allows the system to work effectively within the limited 10-foot lateral space while maintaining compliance with the overall 20-foot tunnel width regulation.
Data Source
AI summary
A vehicle supported mine item positioning apparatus for placing, for example, heavy mining conveyor belt items such as roller assemblies, conveyor frame side rails, frame sections or the like in precise positions for attachment to other conveyor structure, wherein the vehicle can get into cramped quarters in the mine alongside the conveyor and extend, retract, rotate and further manipulate an item pick-up crane mounted on the vehicle, whereby the crane with item pick-up means mounted on an end thereof can pick up and place, e.g., a roller assembly in a precise position and posture on a conveyor frame for making said attachment, and further in a preferred embodiment, the apparatus is provided with second crane means for lifting a moving conveyor belt off of a roller assembly for replacement of said assembly with or without stopping the belt, whereby worker lifting and manipulation of heavy roller assemblies or other heavy mining structures is eliminated.