3D Shearer Control with PID Arm-Height Adjustment
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Solution Overview
Problem
Existing shearer control methods fail to accurately account for seam inclination and height variations, leading to inefficiencies in coal extraction and requiring costly corrective actions.
Innovation Solution
A method and system for controlling a shearer in three dimensions, using a PID controller to adjust the arm height based on a target 3D cutting profile, incorporating a face advance tilt angle error correction, and integrating a PID controller dependent on the retreat progress direction to minimize errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional controllers are used to control the shearer along a predetermined line profile, then the shearer can follow a cutting face path, but the control accuracy deteriorates when accounting for seam inclination and height variations
Solution Approach 1:
The patent transitions from conventional 2D line profile control to 3D control by adding the vertical dimension (arm height adjustment). The controller now manages both horizontal position along the cutting face and vertical position through arm height adjustment, enabling accurate tracking of the shearer drum's 3D trajectory to match seam inclination and height variations.
Solution Approach 2:
The patent implements feedback control by continuously monitoring the actual position of the shearer drum and comparing it with the target 3D cutting profile. The controller adjusts the arm height in real-time based on the error between actual and target positions, ensuring accurate following of the seam geometry throughout the mining operation.
2Productivity
If additional corrective action is taken to account for seam inclination, then the coal extraction efficiency improves, but the device complexity increases
Solution Approach 1:
The patent makes the controller multi-functional by integrating multiple control tasks into a single system: it controls the shearer's horizontal movement along the cutting face, adjusts the arm height vertically, and compensates for seam inclination. This unified approach improves coal extraction efficiency without proportionally increasing complexity, as one controller handles all three functions.
3Productivity
If the shearer operates at high speed to maximize production, then the productivity increases, but the control precision for maintaining target cutting profile decreases
Solution Approach 1:
The patent ensures continuous control action by maintaining real-time feedback and adjustment throughout the shearer's movement. The controller continuously monitors the drum position, calculates the error against the target profile, and applies corrective arm height adjustments without interruption, enabling high-speed operation while preserving cutting profile accuracy through uninterrupted control.
Data Source
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AI summary
The present invention pertains to a method for controlling a shearer in three dimensions, the shearer comprising at least one shearer drum (12) attached to an arm (14) having an adjustable arm height (Z), the method comprising the steps of determining (S10) a current position of the shearer drum (12), calculating (S20) a target 3D cutting profile (18), and controlling (S30) the shearer (10) by adjusting an arm height (Z) to the target 3D cutting profile using a PID controller. The present invention also pertains to a system configured to carry out such method.