Self-advancing Roof Support with Load Sensor Cavity Detection
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Solution Overview
Problem
Longwall mining systems face safety risks due to cavity formations in the mine roof, which are difficult to detect accurately and timely by human operators, leading to potential roof collapses and increased operator fatigue.
Innovation Solution
A self-advancing roof support system with a control system that includes load sensors and hydraulic actuators, allowing for autonomous detection and movement of the roof support to underlying cavities, ensuring prompt and accurate support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human operators manually detect cavity formations in the mine roof, then the system can identify roof deformities, but operator fatigue increases and detection accuracy decreases
Solution Approach 1:
The roof support system performs self-detection of cavity formations through load sensors that automatically monitor roof conditions without requiring manual operator intervention. The system detects changes in load patterns that indicate cavity formations and autonomously responds by advancing the support position.
Solution Approach 2:
The patent replaces the manual visual inspection and judgment process with an automated sensor-based detection system. Load sensors electronically monitor roof conditions and transmit data to a controller, substituting human sensory and cognitive functions with mechanical and electronic systems.
2Reliability
If operators continuously monitor the mine roof for cavity formations, then safety risks can be detected, but operator fatigue increases and response time is delayed
Solution Approach 1:
The load sensors continuously monitor roof conditions without interruption, maintaining constant surveillance of the mine roof. This continuous monitoring eliminates gaps in detection that occur with periodic manual inspections, ensuring that cavity formations are detected immediately when they develop.
Solution Approach 2:
The system incorporates feedback through load sensors that continuously provide information about roof load conditions to a controller. When the controller detects load pattern changes indicating a cavity formation, it immediately triggers an advancement response, creating a closed-loop feedback system that ensures rapid response to safety threats.
3Ease of operation
If the roof support system advances manually based on operator detection, then the system can provide support, but inaccuracies and delays in cavity detection reduce effectiveness
Solution Approach 1:
The roof support system autonomously detects cavity formations through load sensors and automatically advances without requiring manual operator intervention. The system serves itself by performing both detection and response functions, eliminating the inaccuracies and delays associated with human judgment.
Solution Approach 2:
The patent replaces manual detection and decision-making processes with automated electronic sensors and control systems. Load sensors electronically monitor roof conditions and the controller automatically processes this data to determine when advancement is required, substituting human operational processes with mechanical and electronic systems.
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 enhances mine and operator safety by autonomously detecting cavities and moving the roof support into position, reducing operator fatigue and eliminating inaccuracies and delays associated with manual inspection and intervention.
Implementation Method 1
at least one load sensor disposed on the canopy portion. The at least one load sensor is configured to generate a signal indicative of an amount of load borne by the canopy portion
Implementation Method 2
at least one hydraulic actuator whose one end is pivotally coupled to the base, and a canopy portion that is connected to another end of the hydraulic actuator
Data Source
AI summary
A self-advancing roof support for a longwall mining system includes a base, a hydraulic actuator having one end pivotally coupled to the base, and a canopy portion that is connected to another end of the hydraulic actuator. The roof support also includes a load sensor disposed on the canopy portion. The load sensor generates a signal indicative of an amount of load borne by the canopy portion in abutment with a roof of an underground mine site. A controller is communicably coupled to the load sensor and the hydraulic actuator. The controller determines if the signal from the load sensor is suggestive of a cavity adjacent to a zone above the canopy portion. Based on the determination, the controller actuates movement of the hydraulic actuator such that the canopy portion is displaced into a position underlying the cavity.