Crawler Synchronization Control for Articulated Mining Machines
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Solution Overview
Problem
Current continuous haulage systems in underground mining face challenges in synchronizing the movement of crawlers in mobile mining machines, particularly during non-linear movements, requiring precise coordination of speed and direction to prevent collisions and ensure smooth navigation, which is often manual and prone to errors.
Innovation Solution
A system and method that uses sensors and input means to set and regulate driving parameters such as speed, direction, and torque for crawlers, employing PWM signals and hydraulic valves to synchronize crawler movement, reducing manual intervention and ensuring precise navigation through automated control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control is used for crawler synchronization, then operational flexibility is maintained, but synchronization precision and safety deteriorate due to human error
Solution Approach 1:
The control system automatically regulates crawler motor speeds and directions without manual intervention. The system monitors actual speeds of multiple crawlers and autonomously adjusts hydraulic valve positions to maintain synchronization, eliminating the need for continuous manual control while ensuring reliable operation
Solution Approach 2:
The system incorporates speed sensors on each crawler motor that continuously feed back actual speed information to the controller. The controller compares these actual speeds with target speeds and automatically generates control signals to adjust hydraulic valves, creating a closed-loop feedback system that ensures precise synchronization
2Reliability
If automated control system is implemented for crawler synchronization, then synchronization precision and safety improve, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it receives speed feedback from all crawler motors, calculates required speed adjustments based on synchronization requirements, generates control signals for hydraulic valves, and monitors system status. This multi-functional integration reduces the need for separate control components for each crawler
Solution Approach 2:
The system combines the control functions for multiple crawlers into a single integrated control unit. The hydraulic valve system is designed so that a single controller can regulate multiple valves simultaneously, merging what would otherwise be separate control systems into one unified device
3Adaptability or versatility
If different hydraulic pipe lengths are used for right and left crawlers, then individual crawler independence is maintained, but synchronization difficulty increases
Solution Approach 1:
Speed sensors on each crawler motor provide continuous feedback to the controller, which compensates for the different hydraulic pipe lengths. The controller monitors actual speeds and automatically adjusts control signals to ensure all crawlers move at synchronized speeds despite the asymmetric hydraulic configuration
Solution Approach 2:
The system dynamically adjusts control parameters (hydraulic valve positions) based on real-time speed measurements. By changing the control parameters rather than the physical pipe lengths, the system achieves synchronization while maintaining the flexibility of different pipe configurations for each crawler
4Productivity
If multiple inter-connected vehicle units are used, then haulage capacity increases, but coordination complexity and collision risk increase
Solution Approach 1:
The control system is implemented independently in each vehicle unit, with each unit's controller managing its own crawlers based on local speed sensor feedback. This segmentation allows each unit to operate autonomously while maintaining synchronization within the multi-unit system, reducing overall coordination complexity
Solution Approach 2:
The controller design is universal and can be applied to each vehicle unit in the multi-unit system. Each controller performs the same functions (receiving speed feedback, calculating adjustments, generating control signals), allowing standardized deployment across multiple units and simplifying the coordination of complex multi-unit operations
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 system achieves synchronized movement of crawlers in mobile mining machines, enhancing safety and reducing errors by automatically adjusting crawler speeds and directions, even in complex maneuvers and slippery conditions, thereby improving operational efficiency and reducing manual intervention.
Implementation Method 1
The controller is configured to receive the operating value of the driving parameter from the input means and the actual value of the driving parameter from the at least one sensor, and to determine a control signal for each crawler based on the operating value of the driving parameter of the respective crawler and the actual values of the driving parameter of the pair of right and left crawlers comprising the respective crawler
Implementation Method 2
employing PWM signals and hydraulic valves to synchronize crawler movement
Data Source
AI summary
The present disclosure relates to a system and a method of controlling the movement of a tracked mobile mining machine having one or more articulated vehicle units. The control system works by taking input from manual or automated input means, the input serving as a set operating value for at least one driving parameter. The controller generates control signals, which are sent to regulating means that actuate the motor of the mobile mining machine. Using sensors on the machine, actual values of the driving parameter are measured in real-time and fed to the controller for comparison with the original set values. Any difference in the values is compensated for when the controller sends control signals to the regulating means causing readjustment of the driving parameter of the mining machine. The control system is applicable to crawler-driven powered vehicle units to ensure synchronous crawler movement for both linear and non-linear paths.