Fiber Optic Shape Sensing for Longwall Pan Line Joint Monitoring
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Solution Overview
Problem
Existing longwall mining systems lack effective monitoring of pan line conditions, particularly interconnecting joints, which are prone to failure under severe loads, impacting machine performance and operator safety.
Innovation Solution
A fiber optic shape sensing system is integrated into the pan line, with a fiber optic cable disposed within the pan segments and a controller to detect the cable's shape, identify segment positions, and determine faults in interconnecting joints, allowing for automated monitoring and potential termination of operations if a fault is detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring of pan line conditions is performed, then operator awareness of joint conditions is maintained, but operator fatigue increases and safety is compromised
Solution Approach 1:
The patent replaces manual visual inspection and mechanical monitoring methods with an optical fiber sensing system. The optical fiber cable embedded in the pan line structure detects shape changes and joint conditions through optical measurements, eliminating the need for operators to manually monitor pan line conditions and reducing operator fatigue while improving monitoring reliability.
Solution Approach 2:
The pan line structure performs self-monitoring through the embedded optical fiber sensing system. The structural elements themselves (pan segments and joints) provide the sensing capability through the optical fiber embedded within them, enabling the system to monitor its own condition without external intervention or operator involvement.
2Difficulty of detecting and measuring
If traditional monitoring methods are used, then system complexity is kept low, but fault detection capability is insufficient
Solution Approach 1:
The optical fiber cable serves multiple functions: it acts as both a structural element (embedded within the pan line) and a sensing element (detecting shape changes and joint conditions). This multi-functionality improves fault detection capability while minimizing additional system complexity, as the same component performs both structural and monitoring roles.
3Strength
If interconnecting joints are designed for high load capacity, then pan line strength is improved, but joint failure risk under extreme conditions increases
Solution Approach 1:
The optical fiber sensing system provides advance detection of joint degradation and potential failures before actual failure occurs. By continuously monitoring joint shape and position, the system enables preliminary identification of problematic joints, allowing for preventive maintenance or operational adjustments before catastrophic failure happens, thus improving joint reliability while maintaining high strength design.
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 efficient, automated monitoring of pan line conditions, reducing operator fatigue and improving safety by detecting joint failures and preventing operational disruptions, thus enhancing the reliability and safety of longwall mining operations.
Implementation Method 1
The FOSS system includes a fiber optic cable that is disposed along the multiple pan segments and located within the opening of each pan segment. The FOSS system also includes a controller that is communicably coupled to the fiber optic cable. The controller is configured to detect a shape of the fiber optic cable
Data Source
AI summary
A system for monitoring a condition of a pan line associated with a longwall mining system includes multiple pan segments arranged in a successive manner. Adjacently located pan segments are moveably coupled by an interconnecting joint. An underside of each pan segment defines an opening whose axis is parallel to a plane of the associated pan segment. The system also includes a fiber optic shape sensing system that has a fiber optic cable disposed along the multiple pan segments and located within the opening of each pan segment. A controller coupled to the fiber optic cable detects a shape of the fiber optic cable, identifies a position of each pan segment based on the detected shape of the fiber optic cable, and determines if a fault exists in the interconnecting joints between adjacently located pan segments based on the identified positions of respective ones of the adjacently located pan segments.