Hydraulic Support Navigation Sensing for Collision and Inclination Control
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Solution Overview
Problem
Advanced hydraulic supports in coal mine laneways frequently encounter issues such as hitting side walls, obstacles, and uneven lane surfaces, leading to operational delays, economic losses, and safety risks due to lateral collisions and large inclinations.
Innovation Solution
A system incorporating ultrasonic sensors and inclination measurement devices for navigation detection and inclination measurement, which includes a detection device module, a signal transfer and transmission module, and an analysis and processing module to prevent collisions and malfunctions by wirelessly transmitting and analyzing distance and inclination signals to alert workers and control the hydraulic supports' operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If advanced hydraulic supports operate in coal mine laneways without detection systems, then the device complexity is low, but the reliability is poor due to frequent collisions with side walls and obstacles
Solution Approach 1:
The patent applies preliminary action by equipping hydraulic supports with ultrasonic sensors and inclination measurement devices that continuously detect obstacles and terrain conditions before collisions occur. The system performs advance warning and automatic stopping before harmful events happen, preventing lateral collisions and inclination-related malfunctions proactively
Solution Approach 2:
The patent introduces an intermediary control system that includes signal processing units and communication modules between the sensors and the hydraulic support actuators. This intermediary layer processes detection data, determines abnormal conditions, and controls the stopping mechanism, thereby improving reliability without directly increasing the complexity of the hydraulic support structure itself
2Reliability
If hydraulic supports move forwards or horizontally without detection, then the productivity is maintained, but the reliability decreases due to lateral portions hitting side walls
Solution Approach 1:
The patent implements feedback control by continuously monitoring the distance to side walls and obstacles using ultrasonic sensors, and the inclination angle using measurement devices. When abnormal conditions are detected (such as approaching lateral collision thresholds or excessive inclination), the system provides feedback to stop the hydraulic support automatically, preventing collisions while maintaining operational efficiency through timely interventions
3Reliability
If hydraulic supports operate without inclination measurement, then the device complexity is low, but the reliability is poor due to large inclinations causing falls or malfunctions
Solution Approach 1:
The patent replaces traditional mechanical inclination measurement methods with electronic sensors and signal processing systems. By using electronic inclination measurement devices and processing circuits instead of purely mechanical levels or visual inspection methods, the system achieves more precise and reliable inclination detection with reduced mechanical complexity
4Reliability
If multiple sensors and detection devices are installed on hydraulic supports, then the reliability is improved through comprehensive monitoring, but the device complexity increases
Solution Approach 1:
The patent applies merging by integrating multiple detection functions (ultrasonic obstacle detection, inclination measurement, and communication) into a unified detection system. The signal processing unit consolidates data from various sensors, and the communication module transmits all detection information centrally, reducing the complexity of individual components while maintaining comprehensive monitoring capability
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 effectively prevents collisions and malfunctions by providing early warnings and controlling the operation of advanced hydraulic supports, enhancing safety and efficiency in coal mining operations.
Implementation Method 1
the ultrasonic sensor at the front end of the top plate is located on a front side of the top plate of a single advanced hydraulic support, and is used to determine whether there is an obstacle in front of the top plate by emitting an ultrasonic wave and receiving an ultrasonic wave
Data Source
AI summary
A system for navigation detection and inclination measurement of advanced hydraulic supports, including a detection device module, a signal transfer transmission module, connected to the detection device module, and used to integrate ultrasonic signals and inclination signals received from all advanced hydraulic supports and then wirelessly transmit all the signals to an analysis and processing module. The analysis and processing module, connected to the signal transfer transmission module, and used to receive the signals from the signal integration and transmission device for analysis, where if an analysis result shows an abnormal situation, an alarm will b e immediately given to a worker. If the analysis result shows a continuous abnormal situation, or a relatively large value indicating the abnormal situation is generated, a command will be immediately sent to make the advanced hydraulic supports stop operating in a current mode.