Distributed Coal Cutting Device for Longwall Face
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Solution Overview
Problem
The current fully-mechanized coal cutting process in coal mines is inefficient due to the use of a single shearer for coal cutting, leading to low coal cutting efficiency, high equipment costs, and reliability issues, as well as the need for high environmental adaptability, which results in significant production disruptions when the shearer fails.
Innovation Solution
A distributed coal cutting device for a Longwall face, comprising multiple coal cutting units each with a coal cutting machine and two hydraulic supports arranged side by side, allowing for simultaneous coal cutting operations and increased operational flexibility, adaptability, and reduced equipment complexity, enabling multi-point simultaneous coal cutting and improved production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single shearer is used for coal cutting in reciprocating mode, then the equipment structure is simple, but the coal cutting efficiency is low and production capacity is limited
Solution Approach 1:
The patent divides the single shearer into multiple independent coal cutting units (shearers), each capable of independent operation. These units are distributed along the coal wall and work simultaneously at different positions, transforming a single-point cutting system into a multi-point parallel cutting system, thereby significantly improving coal cutting efficiency while maintaining reasonable equipment complexity through modular design
Solution Approach 2:
The patent combines multiple coal cutting units with hydraulic supports and conveyors into an integrated distributed coal cutting system. The coal cutting units are coordinated to work simultaneously while sharing common support and transportation infrastructure, achieving both high productivity through parallel operation and controlled device complexity through system integration
2Productivity
If the shearer size, power and weight are increased to improve yield, then the production capacity increases, but the equipment becomes difficult to manufacture and expensive, and reliability decreases
Solution Approach 1:
Instead of increasing the size and power of a single shearer, the patent segments the cutting function into multiple smaller, standardized coal cutting units. Each unit has moderate power requirements and can be manufactured with standard components, improving reliability through redundancy while achieving high yield through parallel operation of multiple units
Solution Approach 2:
The patent changes the system configuration from one large high-power shearer to multiple smaller units with distributed power. This parameter change allows each unit to operate within reliable power ranges while the collective system achieves the required total yield, and enables easier manufacturing through standardization of smaller components
3Reliability
If a single shearer is used, then the equipment cost is reduced, but once it fails, all machines in the Longwall face must stop production, seriously affecting working efficiency
Solution Approach 1:
The patent segments the coal cutting function into multiple independent units that can operate autonomously. When one unit fails, the others continue production, ensuring production continuity. The modular segmented design allows isolation of failures to individual units rather than system-wide shutdowns
Solution Approach 2:
Each coal cutting unit is designed as an independent functional module with local control capabilities. This local quality independence means that failures in one unit do not propagate to other units, maintaining production continuity while the overall system achieves the required complexity for redundancy and reliability
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 distributed coal cutting device enhances coal cutting production capacity and efficiency by allowing multiple coal cutting machines to operate simultaneously, reduces manufacturing difficulties and costs, and ensures continued production even if one machine fails, improving overall reliability and flexibility.
Implementation Method 1
the two hydraulic supports are arranged side by side, the arrangement direction of the two hydraulic supports is parallel to the coal wall of the Longwall face, the hydraulic supports can support a roof of the Longwall face
Data Source
AI summary
A distributed coal cutting device for a Longwall face of a coal mine includes coal cutting units, where each coal cutting unit includes one coal cutting machine and two hydraulic supports, the two hydraulic supports are arranged side by side, the arrangement direction of the two hydraulic supports is parallel to the coal wall of the Longwall face, and the coal cutting machine is connected with one of the hydraulic supports. According to the device, multiple coal cutting machines are used for simultaneously carrying out coal cutting operation, and single-point coal cutting is changed into multiple-point simultaneous coal cutting, so that the coal cutting production capacity and the production efficiency are greatly improved. The multiple coal cutting machines can derive multiple control modes, so that the production flexibility and adaptability are improved.