Longwall Shearer Control via Inertial Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for controlling a shearer in an underground mine require significant operator assistance due to the lack of automated control systems, posing safety risks in hazardous environments like underground mines.
Innovation Solution
A method for controlling a shearer that involves setting an initial cutting profile and generating a second cutting profile based on actual advancing vectors and orientations, using position and orientation measuring devices to adjust cutting drum heights and reduce operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated control systems are implemented to reduce operator assistance, then safety is improved by minimizing human exposure to hazardous environments, but device complexity increases due to the need for advanced sensors, processors, and control algorithms
Solution Approach 1:
The shearer control system operates autonomously by self-determining its position using inertial sensors and self-adjusting cutting drum positions based on processed terrain data, eliminating the need for continuous operator intervention and reducing human exposure to hazardous mining environments
Solution Approach 2:
The patent replaces manual mechanical control with an automated electronic control system that uses inertial measurement units, processors, and electronic actuators to control shearer movement and cutting drum positioning, substituting human operator actions with automated sensing and control mechanisms
2Productivity
If automated control systems are implemented to reduce operator assistance, then productivity is improved through continuous operation without human fatigue, but device complexity increases due to the need for advanced control mechanisms
Solution Approach 1:
The control system continuously and autonomously determines shearer position, calculates cutting drum trajectories, and adjusts drum positions without human intervention, enabling continuous operation that eliminates fatigue-related productivity losses while maintaining manageable system complexity through integrated self-control
Solution Approach 2:
The automated control system enables continuous mining operations by continuously processing inertial sensor data, continuously calculating optimal cutting paths, and continuously adjusting drum positions, eliminating interruptions caused by operator fatigue, shifts, or manual repositioning
3Manufacturing precision
If cutting drum positions are automatically adjusted based on terrain variations, then manufacturing precision is improved in maintaining accurate cutting profiles, but device complexity increases due to the need for position sensing and control mechanisms
Solution Approach 1:
The control system uses inertial measurement units to continuously feedback the shearer's actual position and orientation, processes this data to determine terrain variations, and automatically adjusts cutting drum positions to maintain accurate cutting profiles despite floor irregularities
Solution Approach 2:
The patent replaces complex mechanical position sensing systems with electronic inertial measurement units and digital processing, achieving precise cutting drum position control through electronic sensing and actuation rather than mechanical linkages and sensors
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The present disclosure generally relates to a method for controlling a shearer (10) in an underground mine. The method comprises setting a first cutting profile (50) including a plurality of desired positions (Di) to be approached by a first cutting drum (12) in a first travel direction (E), advancing the shearer (10) towards the longwall face (2), and generating a second cutting profile (51) including a plurality of desired positions (Ri) to be approached by at least one of the first cutting drum (12) and a second cutting drum (14) in a second travel direction (F) of the shearer (10) based on the set first cutting profile (50), a plurality of actual advancing vectors (vi), and a plurality of shearer orientations (Oi).