Radar Sump Depth Detection for Continuous Miners

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Measuring the sump depth of a continuous miner in mining operations is challenging due to dust, spray, and slippery conditions, which can lead to excessive load on cutter motors and inefficient production.

Innovation Solution

A radar system mounted on the continuous miner transmits radio waves and detects reflections from corner cube reflectors on roof bolts to determine sump depth, with a controller adjusting operations based on the measured depth to maintain optimal sump depth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If sump depth is increased to improve production efficiency, then productivity increases, but excessive load on cutter motors occurs and roof/floor profile becomes unsafe

Engineering Contradiction:

Improveproduction efficiencyVSAvoidload on cutter motors

Core Design Contradiction:

ProductivityVSForce

Solution Approach 1:

The radar system continuously measures the actual sump depth by detecting the distance between the miner and stationary roof bolts, providing real-time feedback to the control system. This feedback loop enables automatic adjustment of sump depth to maintain optimal values, preventing both excessive load from over-sumping and inefficient production from under-sumping.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces traditional mechanical measurement methods (such as encoders on tracks or tires) with a radar-based electromagnetic measurement system. This substitution eliminates measurement errors caused by track/tire slip and dust/spray interference, providing accurate sump depth measurement that enables precise control of cutting load and production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If traditional measurement methods are used to determine sump depth, then device complexity is reduced, but measurement precision deteriorates due to dust, spray, and track slip

Engineering Contradiction:

Improvesystem simplicityVSAvoidsump depth measurement accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical measurement systems (encoders, sensors on tracks/tires) with a radar-based electromagnetic measurement system. Radar waves penetrate dust and spray conditions that obscure optical sensors, and the measurement is independent of track/tire slip, providing accurate sump depth measurement in harsh mining environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses stationary roof bolts as intermediary reference objects for radar measurement. By measuring the distance to these fixed, known-position objects, the system accurately determines miner position and sump depth without being affected by environmental conditions like dust, spray, or track slip.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If optical sensors are used to measure sump depth, then device complexity is minimized, but measurement precision worsens due to dust and spray during cutting

Engineering Contradiction:

Improvesensor system simplicityVSAvoidsump depth detection accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces optical sensors with a radar-based electromagnetic measurement system. Radar waves operate at frequencies that penetrate dust and spray conditions, allowing accurate distance measurement to roof bolts without being obscured by the harsh environmental conditions present during active cutting operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The radar system accurately determines sump depth, enabling automatic adjustments to prevent over-sumping or under-sumping, thereby reducing load on cutter motors and improving production efficiency.

Implementation Method 1

The radar device transmits radio waves and detects reflected radio waves

Methodology Applied

Scientific EffectRadar: Radar

Implementation Method 2

detects reflected radio waves

Methodology Applied

Scientific EffectRadio wave reflection: Reflection

Implementation Method 3

A corner cube reflector can also be attached to the roof bolt to increase accuracy of the radar detection

Methodology Applied

Scientific EffectCorner cube reflection: Retroreflector

Data Source

PatentUS9435201B2Detecting sump depth of a miner

Publication Date: 2016.09.06 JOY GLOBAL UNDERGROUND MINING LLC

AI summary

Systems and methods for operating a mining machine. One system includes a controller, a stationary object, and a radar device. The radar device transmits radio waves toward the stationary object and detects reflections of the radio waves. The controller obtains timing information regarding the radio waves and the reflections. Based on the timing information, the controller is configured to determine a first distance between the radar device and the stationary object before sumping the mining machine into material and a second distance between the radar device and the stationary object after sumping the mining machine into the material. The controller is also configured to determine a sump depth of the mining machine based on the first distance and the second distance, compare the determined sump depth to a predetermined sump depth, and perform at least one automatic action when the determined sump depth does not satisfy the predetermined sump depth.