Longwall Mining Cable Handling System with Predictive Dislodgement Control

Solution Overview

Problem

The cable handling system in longwall mining machines is prone to dislodgement due to the stacking and folding of cables, which can lead to damage and safety hazards, especially with undulations in the mining seam causing cables to rise above tray heights and unravel.

Innovation Solution

A cable handling system with interconnected trays and a controller that determines the profile of the pan line and detects parameters such as span, elevation, skew, and twist of the service line, predicting the likelihood of dislodgement by comparing these parameters to predefined thresholds and alerting operators to prevent accidents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the bretby is folded and stacked numerous times as the shearer moves, then the cable handling system can accommodate shearer travel, but the likelihood of the bretby escaping the tray increases

Engineering Contradiction:

Improvecable handling system accommodation of shearer travelVSAvoidcable containment in tray

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system performs preliminary detection of pan line profile and cable parameters before dislodgement occurs. The controller continuously monitors cable position, tray orientation, and stack height, predicting potential escape scenarios and alerting operators in advance to take preventive action.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements continuous feedback monitoring of cable handling conditions through sensors that detect cable position, tray angle, and stack configuration. This feedback loop enables real-time assessment of dislodgement risk and allows the system to maintain reliable cable containment by alerting operators to adjust conditions before escape occurs.

Inventive Principle:

Principle #23Feedback

2Ease of operation

If the stack of the bretby increases in height, then the cable can be managed during shearer movement, but the likelihood of the bretby rising above the tray side wall and falling out increases

Engineering Contradiction:

Improvecable management during shearer movementVSAvoidcable dislodgement and unraveling

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary detection of pan line profile and cable parameters before dislodgement occurs. The controller continuously monitors cable position, tray orientation, and stack height, predicting potential escape scenarios and alerting operators in advance to take preventive action.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces purely mechanical cable containment with an intelligent monitoring and prediction system. Sensors and controllers detect physical parameters and use this data to predict dislodgement risk, substituting passive mechanical containment with active electronic monitoring and early warning capabilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If undulations in the mining seam cause large changes in pan angles, then the system adapts to terrain variations, but the cable may rise above the tray height and fall out

Engineering Contradiction:

Improvesystem adaptation to terrain variationsVSAvoidcable containment stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system performs preliminary detection of pan line profile and cable parameters before dislodgement occurs. The controller continuously monitors cable position, tray orientation, and stack height, predicting potential escape scenarios and alerting operators in advance to take preventive action.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements continuous feedback monitoring of cable handling conditions through sensors that detect cable position, tray angle, and stack configuration. This feedback loop enables real-time assessment of dislodgement risk and allows the system to maintain reliable cable containment by alerting operators to adjust conditions before escape occurs.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS11149546B2Cable handling system for longwall mining machines

Publication Date: 2021.10.19 CATERPILLAR INC

AI summary

A cable handling system for a longwall mining machine is disclosed. The longwall mining machine includes a shearer configured to move along a pan line to mine material along a mine face. The cable handling system includes a service line configured to carry one or more supply lines to the shearer for facilitating shearer operation. Further, a plurality of interconnected trays accommodates the service line. Moreover, a controller is configured to determine a profile of the pan line; detect one or more parameters associated with the service line in relation to the profile of the pan line; and determine a likelihood of at least a portion of the service line dislodging from the plurality of interconnected trays based on the one or more parameters exceeding a predefined threshold.