Longwall Shearer Pan Line Profile Detection Using Distributed Inclinometers
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Solution Overview
Problem
Longwall mining shearer systems struggle to accurately determine the profile of pan lines, particularly at the ends, due to the elongated shape of the shearer, leading to incorrect shearer arm placement and potential misrepresentation of the mine face profile.
Innovation Solution
A shearing system equipped with a control system that utilizes sensors, including inclinometers, to detect the orientation of both the shearer and consecutively arranged pans beyond the end stop, allowing for precise determination and control of the pan line profile between the end stop and gate end, enabling accurate shearer arm movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the shearer uses its own sensor to determine the pan line profile, then the measurement is straightforward, but the elongated shearer cannot reach the ends of the pan line resulting in incomplete profile detection
Solution Approach 1:
The patent introduces pans as intermediary objects that extend beyond the shearer's reach. These pans are equipped with sensors (inclinometers) to detect orientation data, serving as mediators that provide profile information for the end sections of the pan line that the shearer cannot directly access. The control system integrates data from both the shearer's sensor and the pan sensors to construct the complete profile.
2Loss of information
If the system extrapolates the pan line profile using gate end stop point position, then the profile can be obtained, but the extrapolated profile may misrepresent the actual profile leading to incorrect shearer arm placement
Solution Approach 1:
The patent replaces the mechanical extrapolation method (using gate end stop point positions and pitch angles) with an sensor-based measurement system. Inclinometers mounted on the pans directly measure the orientation and profile of the pan line ends, providing actual measured data instead of calculated estimates, thereby eliminating the inaccuracy inherent in extrapolation methods.
3Reliability
If the shearer stops at the end stop, then the shearer is protected from over-travel, but the profile of the pan line ends beyond the end stop remains undetected
Solution Approach 1:
The patent divides the profile detection function into two segments: the main shearer body detects the profile within its reach, while separate pan-mounted sensors detect the profile at the ends beyond the end stop. This segmentation allows the system to maintain the safety function of the end stop while simultaneously obtaining profile data from the end sections through the distributed pan sensors.
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
This solution ensures accurate shearer arm placement, prevents deviations from desired cut heights, and reduces the risk of uncontrolled roll angles, enhancing operational efficiency and safety in longwall mining.
Implementation Method 1
The set of inclinometers are coupled to the set of consecutively arranged pans and each configured to detect an orientation of a pan of the set of consecutively arranged pans
Implementation Method 2
The shearer includes a shearer arm that is configured to be moved to remove mine material from a mine face. The shearer is positioned on the one or more pans when the shearer arm is disposed between the end stop and the gate end. The shearer also includes a first sensor that is configured to detect an orientation of the shearer
Data Source
AI summary
A shearing system includes a pan line having an end stop, a gate end, and a set of consecutively arranged pans extending from the gate end and having one or more pans disposed beyond the end stop. A shearer is stoppable at the end stop, includes a shearer arm, and is positioned on the one or more pans when the shearer arm is disposed between the end stop and the gate end. A first sensor detects an orientation of the shearer, while second sensors detect an orientation of the set of consecutively arranged pans. A control system determines a profile of the pan line between the end stop and the gate end and controls a movement of the shearer arm based on the profile of the pan line when the shearer arm is disposed between the end stop and the gate end.