Infrared Camera Positioning for Coal Face Thermal Imaging
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Solution Overview
Problem
Existing methods for controlling cutting extraction machines in coal mining using infrared cameras to detect heat radiation from rock layers are hindered by dust, water mist, and trapezoidal distortion, leading to inaccurate measurements, especially in areas with thin or soft rock layers, where heat differences are minimal, and rock layers may shift or become disoriented.
Innovation Solution
Measuring heat outflow from the coal seam's layered structure, with the infrared camera positioned perpendicularly to the working face at a distance from the cutting tools to capture thermal images of maceral interfaces with different thermal conductivity, allowing for a precise definition of conductive layer packages and generation of control data, and optionally using a second camera for verifying coal or rock presence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the infrared camera is arranged close to the cutting tools to minimize heat loss, then heat radiation measurement accuracy is improved, but measurement precision deteriorates due to dust and water mist interference
Solution Approach 1:
The patent introduces an intermediary positioning approach where the infrared camera is placed at an optimal distance from the cutting zone - not immediately adjacent but within a controlled range. This intermediary position allows the use of dust reduction systems (water spray barriers, air curtains) to protect the measurement path while maintaining sufficient proximity for accurate heat radiation detection of the rock layers
2Volume of moving object
If the infrared camera optical axis is arranged at an angle to the working face to fit space constraints, then device compactness is improved, but manufacturing precision deteriorates due to trapezoidal distortion
Solution Approach 1:
The patent transitions from a two-dimensional planar mounting approach to a three-dimensional spatial arrangement. By utilizing the depth dimension along the machine's longitudinal axis, the infrared camera can be positioned at an optimized distance and angle that minimizes trapezoidal distortion while fitting within the machine's structural constraints. This dimensional transition allows for better geometric alignment of the optical axis with the working face
3Difficulty of detecting and measuring
If measurement is performed in the area immediately adjacent to the cutting zone, then heat radiation detection capability is improved, but reliability deteriorates due to dust and water mist
Solution Approach 1:
The patent converts the harmful effects of dust and water mist into beneficial measurement conditions. By positioning the infrared camera to observe areas that are naturally protected or by introducing controlled water spray barriers that reduce dust while allowing thermal radiation to pass, the system transforms the challenging environment into a more favorable measurement condition. The dust reduction systems become part of the measurement strategy rather than obstacles
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 approach provides a more accurate and less distorted thermal image of the coal face, enabling precise determination of conductive layer packages and improved control data for the mining machine, reducing interference from dust and water mist, and accounting for seam structure and experience.
Implementation Method 1
at least one infrared camera arranged on the machine body of the mining machine is used to monitor the heat radiation of the mining face newly exposed by the mining machine
Implementation Method 2
the outflow of heat from the warmer rock body into the face area is measured at the working face
Data Source
AI summary
The invention relates to a method for controlling a cutting extraction machine that can be displaced along a coal face in longwall mining, wherein the radiated heat of the working face (4) newly exposed by the extraction machine is observed by means of an infrared camera (10), and control data for the subsequent extraction travel is generated using said observation. In order to make said method error-free and better suited for practical application, the invention proposes that the observation of the radiated heat is done perpendicular to the working face (4) at a minimum distance from the cutting tools of the extraction machine, and that a guiding layer package (X) having a characteristic sequence of boundaries between layers of differing heat conductivity is determined, and that the course of said guide layer package (X) relative to the boundaries of the face is determined at the end of each extraction travel using the heat images, and that the control data for the next extraction travel of the extraction machine is generated using said course of the guide layer package.