Magnetic Position Detection for Mining Machine Safety Zones
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Solution Overview
Problem
Existing proximity detection systems for operators near large and powerful industrial machines, such as continuous mining machines, face challenges in harsh environments like noise, dust, and unstructured spaces, where traditional sensors like sonar, laser, and radio time-of-flight sensors are unreliable and difficult to maintain, and magnetic field systems lack precise location control and geometric flexibility.
Innovation Solution
A system comprising a transmitter on the machine generating a uniquely encoded magnetic signal, a locator carried by the operator with magnetic proximity signal receiving coils and a digital radio transceiver, and a controller determining the operator's position relative to the machine, allowing for customizable safety zones and precise location detection, with features like dust-proof casing, intrinsically safe components, and user input/display capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sensors like sonar, laser, or radio time-of-flight sensors are used in harsh environments, then detection capability is provided, but reliability deteriorates quickly due to dust, noise, and environmental contamination
Solution Approach 1:
The patent replaces traditional mechanical and optical sensors (sonar, laser, radar) with a magnetic field-based detection system. The transmitter generates a magnetic field that penetrates dust and environmental barriers without being affected by them, while the receiver detects the field strength to determine operator position. This substitution eliminates the contamination issues that plague acoustic and optical sensors in harsh mining environments.
2Adaptability or versatility
If magnetic field systems use a circular safety perimeter, then operator protection is provided, but geometric flexibility deteriorates because arbitrary safety zone shapes cannot be defined
Solution Approach 1:
The patent implements dynamic safety zone definition where the controller can arbitrarily shape safety zones based on the specific machine geometry and operational requirements. Instead of fixed circular perimeters, the system creates customized zones that precisely match the hazardous areas, allowing operators to work safely in non-hazardous regions while maintaining precise location control through magnetic field strength measurements.
3Use of energy by moving object
If transmitters are placed on operators instead of the machine, then power consumption is reduced, but detection range deteriorates due to limited operator power sources
Solution Approach 1:
The patent inverts the traditional approach by placing the high-power transmitter on the machine rather than on the operator. The machine's power source generates a magnetic field that extends throughout the work area, while the lightweight receiver on the operator consumes minimal power to detect the field strength. This inversion allows the machine to provide the necessary power for wide-area detection while keeping the operator's device portable and low-power.
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
Enables reliable and precise detection of the operator's position relative to the machine, allowing for efficient operation while maintaining safety, with customizable safety zones and improved durability in harsh environments.
Implementation Method 1
A magnetic field generator on the machine and a magnetic field sensor carried by the operator. The magnetic field generator creates a magnetic field around the machine.
Implementation Method 2
The magnetic field sensor senses the strength of the magnetic field
Data Source
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AI summary
A system and method for detecting a position of a person or second machine relative to a machine is provided. The system includes a transmitter system located on the machine, a locator for being carried by the person, means for determining the position of said locator relative to the transmitter system, means for defining one or more safety zones around the machine; and warning means for generating a signal when said locator enters into any of said one or more safety zones. The transmitter system includes a controller for generating a uniquely encoded magnetic signal and a plurality of drivers in communication with the controller for transmitting the uniquely encoded magnetic signal. According to the method a uniquely encoded magnetic signal is generated and transmitted around the machine from a transmitter system located- on the machine. The magnetic signal is received and processed at a locator carried by the person.