Resin and Catalyst Injection Control for Mine Roof Bolts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for installing mine roof bolts using two-component resin systems lack efficient control and monitoring, leading to potential issues with resin and catalyst volume management, ratio maintenance, and mixing, which can affect the anchoring process.
Innovation Solution
A computer-implemented method for controlling a pumpable resin system, including resin and catalyst injection cylinders, a hydraulic pump, a hydraulic reservoir, a control panel, and a control module, which manages injection inputs, determines available volumes and pressures, and ensures a predetermined resin-to-catalyst ratio, with features like pre-pressurization and audible alarms for insufficient volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a two-component resin cartridge is used with manual injection, then the system is simple in structure, but the control and monitoring of resin and catalyst volumes, ratios, and mixing is inefficient and error-prone
Solution Approach 1:
The patent replaces manual mechanical injection with an automated pumpable resin system controlled by a computer-implemented method. The system uses electronic control to manage resin and catalyst injection, replacing manual operations with automated volume determination, ratio maintenance, and mixing control through the control module that processes injection inputs and monitors system parameters.
Solution Approach 2:
The control module implements feedback by determining available resin and catalyst volumes, comparing them against required volumes for the injection input, and providing control signals to the hydraulic pump accordingly. The system continuously monitors the injection process and adjusts operations to maintain the predetermined resin-to-catalyst ratio, ensuring accurate control through closed-loop feedback.
2Manufacturing precision
If manual injection methods are used, then the device is simple, but volume management and ratio maintenance are imprecise
Solution Approach 1:
The patent replaces manual injection with an automated pumpable resin system that uses electronic control to determine resin and catalyst volumes within injection cylinders. The control module calculates available volumes based on cylinder positions and provides precise control signals to the hydraulic pump, replacing imprecise manual operations with automated electronic volume management.
Solution Approach 2:
The system uses a control module that creates a digital representation of the physical injection system state. The control module determines volumes by calculating based on cylinder positions and uses this information to control the injection process, effectively using information copying and processing to achieve precise volume control without direct mechanical measurement.
3Reliability
If automated control is implemented, then volume and ratio control is precise, but the system becomes more complex
Solution Approach 1:
The control module serves multiple functions: determining resin and catalyst volumes, comparing available volumes against requirements, controlling the hydraulic pump, monitoring injection pressure, and maintaining the predetermined resin-to-catalyst ratio. By consolidating these functions into a single multi-functional control module, the system achieves high reliability without proportionally increasing overall system complexity.
Solution Approach 2:
The patent combines volume determination, ratio maintenance, and injection control functions into an integrated pumpable resin system. The control module merges multiple control tasks into a unified system that manages resin and catalyst injection simultaneously, ensuring consistent ratio maintenance through coordinated control of both components rather than separate independent controls.
4Manufacturing precision
If resin and catalyst are injected simultaneously without pre-pressurization, then the process is faster, but mixing and injection accuracy deteriorate
Solution Approach 1:
The control module implements pre-pressurization by determining available volumes and generating control signals to pressurize the resin and catalyst cylinders before the actual injection begins. This preliminary action ensures that both components are ready for simultaneous injection at the correct pressure, improving injection accuracy and mixing without significantly delaying the overall process through efficient sequential preprocessing.
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 system ensures accurate and efficient injection of resin and catalyst, maintaining the required ratio, improving the anchoring process by preventing errors and waste, and enhancing operational efficiency.
Implementation Method 1
A computer-implemented method for controlling a pumpable resin system including resin and catalyst injection cylinders, a hydraulic pump, a hydraulic reservoir, a control panel, and a control module
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A computer-implemented method for controlling a pumpable resin system (370) comprising resin and catalyst injection cylinders, a hydraulic pump, a hydraulic reservoir, a control panel (414), and a control module (372), the method comprising: receiving (604)an injection input from the control panel; determining (610)with at least one processor resin and catalyst volumes within the resin and catalyst injection cylinders; determining with at least one processor whether sufficient volumes of resin and catalyst are available for executing the injection input; generating (620, 622) a signal for the hydraulic pump to actuate the resin and catalyst cylinders; and determining (624) with at least one processor whether a resin and catalyst value corresponding to the injection input has been obtained.