Infrared Horizon Control for Longwall Mining Strata Detection
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Solution Overview
Problem
Existing mining methods struggle to accurately control the horizon in longwall mining, leading to potential cutting into overlying or underlying strata, which causes equipment overload, dilutes product content, and increases dust, affecting safety.
Innovation Solution
A method and apparatus using infrared radiation to observe temperature contrasts at the fresh cut product face, determining height coordinates of these contrasts to generate signals for horizon control, and an apparatus with image acquisition, signal processing, and output components to provide accurate horizon control signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional horizon control methods are used, then mining operation can proceed, but cutting into overlying or underlying strata occurs causing equipment overload, diluted product content, and increased dust
Solution Approach 1:
The patent replaces traditional mechanical horizon control methods with an optical/infrared-based detection system. An infrared camera captures thermal radiation from the fresh cut product face, and image processing algorithms automatically determine horizon position and generate control signals, eliminating the need for manual mechanical adjustment and improving precision.
Solution Approach 2:
The system continuously monitors the fresh cut product face using infrared radiation detection and feeds back real-time horizon position information to the mining machine control system. This closed-loop feedback enables dynamic adjustment of the cutter position to prevent cutting into strata while maintaining optimal mining conditions.
2Measurement precision
If manual horizon control is used, then equipment complexity is reduced, but measurement precision and manufacturing precision are insufficient leading to strata cutting
Solution Approach 1:
The patent creates an optical copy of the fresh cut product face through infrared radiation detection. Instead of direct mechanical measurement, the system captures thermal radiation patterns which serve as a digital replica of the horizon position, enabling precise measurement through image processing algorithms.
Solution Approach 2:
The patent introduces infrared radiation as an intermediary between the physical horizon and the control system. The infrared camera detects thermal patterns that mediate the measurement process, converting physical horizon position into detectable thermal signals for automated processing and control signal generation.
3Manufacturing precision
If infrared observation is used to detect temperature contrasts, then horizon control precision is improved, but the system complexity increases with image acquisition and processing components
Solution Approach 1:
The patent divides the image processing system into distinct functional modules: image acquisition component, signal processing component, height position calculation component, and output signal generation component. This segmentation allows each module to perform specific functions independently, making the complex system more manageable and maintainable.
Solution Approach 2:
The sensing apparatus is designed with multi-functional capabilities where the infrared camera serves both as a detection device and an imaging device, while the signal processing component handles multiple tasks including temperature contrast detection, horizon position determination, and control signal generation, reducing the need for separate dedicated components.
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 effectively prevents cutting into strata, reduces equipment load, maintains product quality, and enhances safety by providing precise horizon control, minimizing dust and equipment damage.
Implementation Method 1
visually observing the IR radiation from the fresh cut product face at a position immediately adjacent the cutter
Implementation Method 2
Noting any temperature contrast regions from the IR observation between an upper limit of observation and a lower limit of observation
Data Source
AI summary
A method and apparatus for horizon control in a mining operation where fresh product 3 is cut from a seam 1. The cutting exposes a fresh cut product face 25. The fresh cut product face 25 is observed at a position immediately adjacent a cutter 11. Any temperature contrast regions from an IR observation between an upper limit of observation and a lower limit of observation are noted. At least one height co-ordinate position of a temperature contrast region 33 is determined and an output signal provided of the determined height co-ordinate position so that the output signal can be used as a horizon datum for horizontal control.