Laser Alignment System for Longwall Mining Machine
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Solution Overview
Problem
In longwall coal mining, maintaining proper face alignment of the mining machine with the mineral panel is challenging due to factors like operator error, floor or roof unevenness, and hydraulic component deterioration, leading to reduced productivity from misalignment.
Innovation Solution
A laser-based alignment system is integrated into the mining machine to detect angular misalignment with the roof support, using a light source and a roof support guide, allowing operators to adjust the machine's tilt via hydraulic jacks to ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual alignment methods are used, then operational simplicity is maintained, but alignment precision deteriorates due to operator error and lack of real-time feedback
Solution Approach 1:
The patent implements a feedback mechanism where a laser light source projects a beam onto the roof support, and the position of the light spot on the support surface provides real-time visual feedback about the mining machine's alignment status. This allows operators to continuously monitor and adjust alignment without complex electronic sensors or automated control systems.
Solution Approach 2:
The laser light beam serves as an intermediary between the mining machine and the roof support, translating the alignment relationship into a visible spatial indicator. The light spot position on the roof support acts as a mediator that communicates alignment status to the operator in an intuitive visual form, avoiding direct measurement complexity.
2Measurement precision
If frequent alignment checks and adjustments are performed, then alignment precision is maintained, but productivity is reduced due to additional operational steps
Solution Approach 1:
The alignment system is designed to be self-indicating through the laser light spot position on the roof support. The visual feedback mechanism allows operators to perform quick self-checks and adjustments without requiring external measurement tools or complex procedures, enabling rapid alignment verification that minimizes disruption to the mining workflow.
3Difficulty of detecting and measuring
If alignment detection systems are added to the mining machine, then alignment detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs a simple laser light source and uses the existing roof support surface as the detection target. Rather than installing complex sensors, detectors, or measurement instruments on the mining machine, the system uses inexpensive laser technology and the already-present roof support structure, significantly reducing system complexity and cost while providing effective alignment detection 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 enables precise alignment of the mining machine with the panel face, reducing the need for additional cuts and enhancing productivity by providing an easy method for operators to correct misalignment in real-time.
Implementation Method 1
The alignment means comprises a light source in the form of a laser on the mining machine, and directed toward the roof support
Data Source
AI summary
A mining machine includes a light source and a roof support guide for detecting the relative angular alignment between the mining machine and the roof support. The light source in the form of a laser on the mining machine, directed toward the roof support. The roof support guide is on the roof support above the mining machine, so that when the alignment between the mining machine and the roof support is as desired, light from the light source falls in a predetermined location relative to the roof support guide. When the mining machine is not in proper alignment with the roof support, the light source does not fall within the predetermined location relative to the roof support guide. When a mining machine operator detects that the light from the light source is not falling within the predetermined location relative to the roof support guide, the operator then adjusts the tilt of the mining machine using hydraulic jacks to cause the light from the light source to again fall within the predetermined location relative to the roof support guide.