Longwall Shearer Path Detection for Conveyor Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In longwall mining systems, the uneven ore face alignment causes misalignment of the armored face conveyor with the ore face, leading to inefficiencies and challenges in automating the mining process.
Innovation Solution
A system comprising a detection device in the maingate roadway, a first indicator device on the shearer, and a controller that determines the shearer path and generates an indication of face alignment, allowing for real-time monitoring and correction of the conveyor's alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the armored face conveyor is used to transport ore along the ore face, then ore transportation is enabled, but misalignment with the uneven ore face occurs
Solution Approach 1:
The system dynamically adjusts the conveyor alignment by continuously monitoring the shearer position and ore face geometry, allowing the conveyor to adapt its position and orientation in real-time to maintain optimal alignment with the uneven ore face while preserving transportation capability
Solution Approach 2:
The system implements feedback control by detecting the shearer path and ore face alignment status, then using this information to generate corrective signals that adjust the conveyor position, creating a closed-loop control system that maintains alignment despite face unevenness
2Productivity
If the shearer moves along the uneven ore face, then mining operation continues, but the shearer path deviates from ideal alignment
Solution Approach 1:
The system performs preliminary detection of the shearer position and ore face geometry before the shearer completes its cutting cycle, allowing the control system to predict and compensate for alignment deviations in advance, maintaining both continuous operation and precise path control
Solution Approach 2:
Real-time feedback from position sensors and ore face detection devices enables the system to continuously monitor shearer path deviations and generate corrective control signals, ensuring the shearer maintains optimal alignment with the ore face throughout the mining operation
3Measurement precision
If detection devices and control systems are added to monitor face alignment, then alignment precision improves, but system complexity increases
Solution Approach 1:
The detection device is designed to perform multiple functions: detecting shearer position, mapping ore face geometry, and monitoring alignment status, thereby achieving high measurement precision without proportionally increasing system complexity through a multi-functional integrated sensor system
Solution Approach 2:
The system uses the existing shearer and conveyor infrastructure as part of the detection and control mechanism, where the shearer itself serves as a reference point for alignment detection, reducing the need for additional complex external measurement equipment
Data Source
AI summary
Systems and methods are provided for detecting face alignment and face steering of a longwall mining system. The system includes a detection device mounted in a maingate roadway and a first indicator device mounted on a shearer of the longwall mining system to indicate a position of the shearer to the detection device. The system further includes a controller coupled to the detection device. The controller determines a shearer path of the shearer as the shearer moves along an ore face. The shearer path is determined based on a signal from the first indicator device received by the detection device. The controller generates an indication of face alignment based on the shearer path.