Longwall Shearer Pitch Control via Real-Time Monitoring
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Solution Overview
Problem
Longwall mining systems face challenges in maintaining the optimal pitch angle of the shearer, which can lead to downtime, damage, and extraction problems due to irregularities in the mineral seam and unsupported overlying strata, as existing monitoring systems fail to efficiently control the cutter drum position within desired pitch ranges.
Innovation Solution
A method and device that utilize a processor-based monitoring module to obtain and analyze pitch angle information, determining if the current pitch angle is within a desired range and adjusting the cutter drum position accordingly, ensuring the shearer operates within a predetermined pitch angle range to prevent crashes and tipovers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the shearer operates in irregular mineral seams with unsupported overlying strata, then the mining system can extract mineral, but the pitch angle becomes unstable leading to downtime and damage
Solution Approach 1:
The system performs preliminary monitoring of pitch angle and determines whether it is within the desired range before critical failures occur. By continuously monitoring and evaluating pitch angle data in advance, the system can take corrective actions proactively, preventing downtime and damage associated with crashes and tipovers during mineral extraction operations
Solution Approach 2:
The system implements a feedback mechanism where pitch angle information is continuously obtained, evaluated against desired ranges, and used to control the position of the cutter drum. This closed-loop feedback ensures the shearer maintains stable operation by automatically adjusting the cutter drum position based on real-time pitch angle measurements, resolving the contradiction between maintaining productivity and ensuring reliability
2Ease of operation
If the pitch angle is not monitored and controlled, then the shearer can operate freely, but crashes and tipovers occur causing downtime and damage
Solution Approach 1:
The system enables the shearer to self-monitor and self-correct its pitch angle through automated monitoring and control mechanisms. The processor automatically obtains pitch angle information, evaluates whether it is within the desired range, and controls the cutter drum position without requiring constant manual intervention, thus maintaining ease of operation while preventing crashes and tipovers
Solution Approach 2:
The system replaces manual mechanical monitoring and adjustment operations with an automated electronic monitoring and control system. The processor-based monitoring module substitutes for manual operators, using electronic sensors and control algorithms to maintain pitch angle within desired ranges, thereby preventing harmful events while maintaining operational simplicity
3Device complexity
If the cutter drum position is not adjusted based on pitch angle, then the system structure remains simple, but extraction problems occur due to pitch angle irregularities
Solution Approach 1:
The processor-based monitoring module performs multiple functions: obtaining pitch angle information from sensors, evaluating whether the pitch angle is within the desired range, and controlling the cutter drum position. By consolidating these functions into a single multi-functional module, the system achieves effective pitch angle control without proportionally increasing device complexity, thus maintaining extraction efficiency
4Device complexity
If manual monitoring of pitch angle is used, then the system is simpler, but response time is slow leading to downtime
Solution Approach 1:
The system implements continuous automated monitoring of pitch angle through processor-based control that operates without interruption. The processor continuously obtains pitch angle information, evaluates it against desired ranges, and adjusts the cutter drum position in real-time, eliminating the response delays inherent in manual monitoring and preventing downtime caused by delayed detection of pitch angle problems
Data Source
AI summary
A system and corresponding method of monitoring a longwall shearing mining machine in a longwall mining system, where the shearing mining machine includes a shearer having a cutter drum, the method includes obtaining, by a processor, desired pitch angle information, and receiving, by the processor, a pitch angle indicative of a current pitch position of the shearer. The method also includes determining, by the processor, whether the pitch angle is within a desired pitch angle range, and controlling, by the processor, a position of the cutter drum based on whether the pitch angle is within the desired pitch angle range. The desired pitch angle range is based on the desired pitch angle information.