Redundant Brake Channel Control for Mining Conveyor Braking
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Solution Overview
Problem
Modern shaft conveyor systems face increased complexity in brake systems, leading to potential malfunctions that can result in safety risks, as existing pressure limitation valves are not adjustable during operation and lack reliable failure probability assessments, particularly in scenarios like power failures, necessitating a solution for flexible and reliable braking systems.
Innovation Solution
A multi-channel brake system with redundant pressure control paths and secure Central Processing Units (CPUs) to regulate valve arrangements, ensuring continuous operation even in fault conditions, with each brake channel having a main and backup pressure control path, and multiple CPUs for fail-safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanically adjustable pressure relief valves are used, then pressure control is achieved, but the valves cannot be adjusted during operation
Solution Approach 1:
The patent replaces static mechanically adjustable pressure relief valves with dynamic electro-hydraulic proportional valves that can be continuously adjusted during operation through electronic control signals, enabling real-time pressure adaptation to varying operational requirements
2Adaptability or versatility
If proportional valves for pressure control are used, then continuous pressure adjustment is possible, but failure probability assessment is limited to extreme positions only
Solution Approach 1:
The patent implements a feedback mechanism where the actual valve position and pressure are continuously monitored and reported back to the control system, enabling comprehensive failure probability assessment across the entire operating range rather than only at extreme positions
Solution Approach 2:
The patent replaces traditional mechanical pressure relief valves with electro-hydraulic proportional valves controlled by electronic systems, allowing for continuous monitoring and assessment of valve state throughout the full range of motion, not just at terminal positions
3Adaptability or versatility
If multiple valves with different preset pressure values are used, then various pressure levels can be achieved, but the system complexity increases
Solution Approach 1:
The patent employs a single electro-hydraulic proportional valve that can assume multiple pressure control functions through electronic regulation, replacing the need for multiple mechanically preset valves with different pressure values, thereby reducing system complexity while maintaining pressure level variability
4Reliability
If constant-force braking systems are used, then functional safety is achieved, but flexibility across different hoisting machines is limited
Solution Approach 1:
The patent replaces constant-force braking systems with dynamically controllable electro-hydraulic proportional braking systems that can adapt braking characteristics to different hoisting machine types and load conditions through electronic control, maintaining functional safety while enhancing versatility
Data Source
Figure 1
AI summary
Braking system for use in shaft and inclined conveyor systems in mining, with several brake channels (10.1, 10.2, 10.3, 10.n) for releasing or applying brake force generators (4.1, 4.2, 4.3, 4.n) to the intended braking surface (2) or for adjusting the respective braking force to provide the required braking deceleration, wherein a first main pressure control path (12.1, 12.2, 12.3, 12.n) and a second secondary pressure control path (14.1, 14.2, 14.3, 14.n) that activates in the event of a fault are provided for each brake channel (10.1, 10.2, 10.3, 10.n), and wherein a plurality of, preferably safe, Central Processing Units (CPUs) (16.1, 16.2, 16.3, 16.n) with associated signal and voltage supply for redundant control of the main (12.1, 12.2, 12.3, 12.n) and secondary pressure control paths (14.1, 14.2, 14.3, 14.n) several brake channels (10.1, 10.2, 10.3, 10.n) are provided, wherein each, preferably safe, CPU (16.1, 16.2, 16.3, 16.n) is for controlling the main pressure control path (12.1, 12.2, 12.3, 12.n) at least one associated brake channel (10.1, 10.2, 10.3, 10.n) and a secondary pressure control path (14.1, 14.2, 14.3, 14.n) at least one other of the several brake channels (10.1, 10.2, 10.3, 10.n) is provided.