Mining Machine Heading Control Using Lidar Rib Reference
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Solution Overview
Problem
Controlling the heading of a mining machine while cutting into a mineral seam is challenging due to the absence of sensors or reference points ahead of the machine, and the ineffectiveness of GPS and gyroscopes in underground environments with high vibration and slow movement.
Innovation Solution
The use of machine-mounted lidar sensors to measure previously cut features behind and beside the mining machine, integrating this data with other sensors like cameras or ultra-wideband devices to control the heading, allowing for precise adjustment of the cutting path without external sensors or emitters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If GPS and gyroscopes are used for heading control, then positioning accuracy is improved, but they become ineffective in underground environments with high vibration and slow movement
Solution Approach 1:
The patent replaces GPS and gyroscope-based mechanical/inertial systems with an optical measurement system using laser emitters and detectors mounted on the mining machine. This optical system measures the actual position of the cutting head relative to the rib by detecting light reflections from reference points on the rib surface, thereby achieving reliable heading measurement in underground environments where traditional systems fail due to vibration and signal loss.
2Device complexity
If manual visual inspection is used for heading control, then the system complexity is reduced, but the accuracy and productivity deteriorate due to observation difficulty and frequent corrections
Solution Approach 1:
The system enables automatic heading control by equipping the mining machine with self-contained laser emitters and detectors that continuously measure the position of the cutting head relative to the rib. The control system automatically processes these measurements and adjusts the machine's heading without requiring manual visual inspection, thereby maintaining operational simplicity while dramatically improving measurement precision and reducing the need for corrective cuts.
3Measurement precision
If sensors are placed ahead of the machine for measurement, then forward-looking measurement is enabled, but it becomes impossible since the material has not yet been removed
Solution Approach 1:
Instead of attempting to measure ahead of the cutting head where no reference exists, the patent inverts the approach by mounting sensors on the machine itself to measure the position of the cutting head relative to the already-cut rib surface. The laser emitters project light onto reference points on the rib, and detectors measure the reflected light to determine the cutting head's actual position, enabling accurate measurement in the only available reference frame.
4Manufacturing precision
If frequent manual corrections are made to maintain heading, then adherence to mine plan is improved, but productivity is reduced due to cutting interruptions
Solution Approach 1:
The patent implements a continuous feedback control system where laser detectors continuously measure the actual position of the cutting head relative to the rib, this information is fed to the control system which automatically adjusts the machine's heading to maintain the desired cutting path. This closed-loop feedback eliminates the need for frequent manual corrections and interruptions, thereby maintaining high cutting path adherence while preserving productivity through uninterrupted automated control.
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 method enhances the accuracy of heading control, reducing manual corrections and improving productivity by enabling the mining machine to adhere to a mine plan, even in underground environments where traditional methods fail.
Implementation Method 1
a lidar sensor mounted to the mining machine, the lidar sensor configured to emit a pulse of light towards a previously cut mining surface and receive a pulse of light reflected back from the previously cut mining surface
Data Source
AI summary
Methods and systems for controlling the heading of a mining machine while the mining machine performs a cutting operation. One system includes a cutting system and a set of left and right tracks of the mining machine. The system also includes a lidar sensor mounted to the mining machine. The system also includes an electronic processor configured to receive the data from the lidar sensor. The electronic processor is also configured to determine a current heading of the mining machine based on the data received from the lidar sensor and compare the current heading to a target heading of the mining machine. In response to the current heading not being different from the target heading of the mining machine by a predetermined amount, the electronic processor is configured to control the mining machine to adjust the current heading of the mining machine.