Hydraulic Prop Pressure Intensifiers for Precise Shield Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In underground mining, existing hydraulic shield support systems face challenges in achieving the increased pressure required to support larger rock surfaces, as they rely on inefficient hydraulic fluid pressurization methods that are not easily adjustable or reliable.
Innovation Solution
A pressure intensifier system is introduced, comprising a housing with a low-pressure input and high-pressure output, an intensifier piston, a directional control valve, and a switching valve, allowing for individual pressure control of hydraulic props using pressure sensors, and featuring a mechanically actuated 3/3 way valve for autonomous operation and reliable pressure intensification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional hydraulic systems are used to support larger rock surfaces, then the load capacity must be increased, but the system pressure becomes difficult to control and adjust
Solution Approach 1:
The hydraulic system is segmented by providing individual pressure intensifiers for each hydraulic prop rather than a single centralized pressure system. This allows independent pressure control and adjustment for each prop, enabling precise load distribution across the shield while supporting larger rock surfaces.
Solution Approach 2:
The system changes the pressure parameter locally at each prop using adjustable pressure intensifiers with variable pressure settings. This enables independent modification of pressure parameters for each hydraulic prop, allowing optimization of load distribution and ease of operation without affecting the entire system.
2Force
If higher pressure is applied to support larger rock surfaces, then the load capacity increases, but the reliability of pressure control decreases
Solution Approach 1:
By segmenting the pressure control function into individual pressure intensifiers for each prop, the system achieves reliable pressure control at each location independently. Each intensifier maintains precise pressure control through its own control mechanism, preventing system-wide pressure fluctuations and improving overall reliability.
Solution Approach 2:
The system incorporates pressure sensors that provide feedback on the actual pressure at each prop. This feedback is used by the control unit to adjust and maintain the desired pressure levels, ensuring reliable pressure control even when supporting larger rock surfaces with higher loads.
3Device complexity
If centralized hydraulic pressure systems are used, then the device complexity is reduced, but the precision of individual pressure control is lost
Solution Approach 1:
The system segments pressure control into individual units while using a modular pressure intensifier design that minimizes overall complexity. Each prop has its own pressure intensifier with standardized components, allowing precise individual control without requiring a completely complex custom system for each prop.
Solution Approach 2:
The pressure intensifiers use universal, standardized components and control mechanisms that can be applied to each prop. This multi-functional approach allows the same design to be replicated across multiple props, maintaining individual precision while avoiding the need for completely unique complex systems for each unit.
4Ease of operation
If pressure intensifiers are added to each hydraulic prop, then individual pressure control is improved, but the device complexity increases
Solution Approach 1:
The pressure intensifier is merged with the hydraulic prop assembly as an integrated unit, reducing the need for separate external pressure control components. This combination simplifies the overall system architecture while maintaining individual pressure adjustment capability for each prop.
Solution Approach 2:
The pressure intensifier design uses universal, standardized components that can be replicated across multiple props without requiring unique complex designs for each unit. This approach improves individual pressure adjustment while minimizing the increase in overall device complexity through component standardization.
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
This solution enables precise pressure adjustment for each hydraulic prop, reducing overall system pressure requirements and ensuring reliable operation by directly increasing pressure at the prop, thus enhancing the stability and efficiency of the hydraulic shield support system.
Implementation Method 1
The intensifier piston (72) is configured to increase the pressure of hydraulic fluid in the high-pressure chamber (74) by moving into the high-pressure chamber (74) when hydraulic fluid at the first pressure is supplied to the low-pressure chamber (73)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
In a hydraulic shield support system (100), a plurality of pressure intensifiers (21) are respectively provided for a plurality of hydraulic props (8). Each pressure intensifier (21) is operated to increase a system pressure (P) to an increased pressure for supplying fluid at the increased pressure to a pressure chamber (18) of the associated hydraulic prop (8). The plurality of pressure sensors (61) measure the pressures of the fluid supplied to the respective hydraulic props (8). A control unit (80) sets a plurality of desired pressures for the plurality of hydraulic props (8), and stops operation of the respective pressure intensifiers (21) when the set desired pressure has been reached.