Heading Machine Cusp Cutter Segmentation
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Solution Overview
Problem
Existing mining machines leave unmined sections on the roof, floor, and side walls, known as kerfs or cusps, which can create hazards and require additional cutting passes, increasing operational risks and costs.
Innovation Solution
A heading machine equipped with parallel cutting rotors and a separate cusp cutter, allowing for efficient removal of side wall cusps without the need for overlapping cutting passes, using a compact and economical design that minimizes energy consumption and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a larger sized roller having increased diameter is used to remove cusps on the side wall, then the cusp removal capability is improved, but the machine becomes bulkier and heavier, manufacturing costs increase significantly, and energy consumption increases
Solution Approach 1:
The cutting function is segmented into two separate components: a moderate-sized roller for main cutting and a dedicated cusp cutter for removing side wall cusps. This segmentation allows each component to be optimized for its specific function rather than requiring one oversized roller to perform all cutting tasks, thereby reducing overall machine weight while maintaining effective cusp removal capability.
Solution Approach 2:
The cusp cutting function is extracted from the main roller and implemented as a separate dedicated cusp cutter. This extraction allows the main roller to remain moderate in size while the specialized cusp cutter handles the specific task of removing side wall cusps, avoiding the need for a bulkier and heavier roller design.
2Productivity
If a larger sized roller having increased diameter is used to remove cusps on the side wall, then the cusp removal capability is improved, but manufacturing costs increase significantly
Solution Approach 1:
The cutting system is divided into a moderate-sized roller and a separate cusp cutter, allowing each component to be manufactured at optimal scales. This segmentation avoids the need to manufacture one large expensive roller, thereby reducing overall manufacturing costs while maintaining effective cusp removal.
Solution Approach 2:
The cusp cutting function is extracted as a separate dedicated device rather than being integrated into a larger roller. This extraction allows for more economical manufacturing of smaller, specialized components compared to manufacturing one large roller that would perform all cutting functions.
3Productivity
If a larger sized roller having increased diameter is used to remove cusps on the side wall, then the cusp removal capability is improved, but energy consumption increases
Solution Approach 1:
The cutting workload is segmented between a moderate-sized roller and a dedicated cusp cutter. This segmentation allows the moderate roller to operate at lower energy consumption levels while the specialized cusp cutter handles the remaining cusp material, reducing total energy consumption compared to using one large high-energy roller.
Solution Approach 2:
The cusp cutting function is extracted and performed by a separate dedicated device with smaller mass and lower moment of inertia, requiring less energy to accelerate and operate compared to a larger roller, thereby reducing overall energy consumption while maintaining effective cusp removal.
4Area of stationary object
If overlapping cutting profiles are used by cutting heads, then the cutting coverage is improved, but the machine structure becomes more complex and requires additional drive means
Solution Approach 1:
The cutting system uses separate dedicated components (cutting heads and cusp cutter) with distinct functions positioned at different locations. This segmentation allows for simpler individual components compared to a complex overlapping roller system, reducing overall machine structure complexity while maintaining comprehensive cutting coverage.
Data Source
Figure 1
Figure 2a~2c
Figure 3a~3b
AI summary
A heading machine includes first and second rotating cutting heads having respectively an axis of rotation extending substantially in a longitudinal direction of the machine, a first cutting roller having an axis of rotation extending substantially horizontal and transverse to the longitudinal direction of the machine, and a further cutting device supported on the cutting frame and adapted to cut off the cusps of unmined material left on side wall. The machine further includes a side stabilizer, and can cut a rectangular profile without leaving cusps left on the side wall.