Fiber Optic Shape Sensing for Highwall Miner Cutter Module Position
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Solution Overview
Problem
Current highwall mining systems face challenges in accurately determining the position and orientation of the cutter module relative to the highwall miner frame, especially when navigating undulating coal seams, and in managing the routing of hydraulic and water hoses as the cutter module penetrates deep into the coal seam.
Innovation Solution
A fiber optic shape sensing system is employed, comprising an interrogation module, a reference frame, and a fiber bundle attached to the cutter module, which provides strain information to compute the position and orientation of the cutter module relative to the highwall miner frame, while a reel-mounted hose chain system efficiently manages fluid supply lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fiber optic gyros are used to determine position and orientation, then measurement capability is provided, but the system cannot accurately track undulating coal seams and the fiber optic cable does not provide shape information
Solution Approach 1:
The fiber optic cable is designed to serve dual functions: as a communication conduit for fiber optic gyro signals and as a shape sensing element. By integrating both functions into a single component, the system obtains both orientation data from the gyro and positional/shape data from the cable deformation, eliminating the need for separate sensing systems and fully utilizing the fiber optic infrastructure already present in the mining equipment.
2Length of moving object
If push beams are continually added as the cutter module penetrates deeper into the coal seam, then the cutter module can reach deeper seams, but the hose chain becomes increasingly complex to manage and route
Solution Approach 1:
The hose chain system is designed with dynamic characteristics that allow it to adapt to changing conditions as push beams are added. The hose chain can extend, retract, and reconfigure itself as the cutter module penetrates deeper into the coal seam, maintaining flexibility and manageability despite the increasing length and number of connections required.
3Reliability
If a robust routing system is implemented for hydraulic and water lines, then fluid supply reliability is improved, but the overall system complexity increases
Solution Approach 1:
The hydraulic fluid lines and water lines are merged into a single integrated hose chain structure. This consolidation reduces the number of separate routing systems needed while maintaining reliable fluid supply to the cutter module. The combined hose chain is managed as one system rather than multiple independent systems, simplifying installation and maintenance.
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 enables precise determination of the cutter module's position and orientation, enhancing coal seam tracking and recovery efficiency, and effectively routes fluid supply lines, even in deep and undulating coal seams.
Implementation Method 1
A fiber optic shape sensing system associated with the cutter module includes an interrogation module, a reference frame fixed to the highwall miner frame, and a fiber bundle joined to the interrogation module at a proximal end and to the cutter module at a distal end. The interrogation module is configured to receive strain information from the fiber bundle
Data Source
AI summary
A system for determining the position and orientation of a cutter module relative to a frame of a highwall miner is provided. The cutter module is attached to the highwall miner by a string of push beams and moveable relative to the highwall miner. A reel is rotatably mounted to the highwall miner frame and configured to feed out a hose chain that supplies fluid to the cutter module. A fiber optic shape sensing system is associated with the cutter module is configured to receive strain information from the fiber bundle and compute the location of at least one position of the fiber bundle that is associated with the cutter module relative to the reference frame.