Virtual Field-Based Track Protection for Mining Dipper
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Solution Overview
Problem
Collisions between the dipper and tracks of a mining machine can occur due to operator error, leading to damage to the machinery and the dipper, and existing solutions fail to effectively prevent or mitigate these collisions.
Innovation Solution
A system and method that limit dipper movements based on proximity to the tracks by defining virtual three-dimensional fields for swing, crowd, and hoist motions, restricting these motions as the dipper approaches the tracks, mimicking the increasing repelling forces of magnets with the same poles, thereby preventing or reducing collision severity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dipper is allowed to move freely in all directions during mining operations, then the productivity and operational efficiency are improved, but the risk of collision with tracks increases causing machinery damage
Solution Approach 1:
The system performs preliminary action by establishing virtual three-dimensional fields around the tracks before any collision can occur. These virtual fields define protected zones in space that preemptively restrict dipper movement paths, preventing collisions before they happen while allowing full operational freedom outside these zones.
Solution Approach 2:
The patent introduces an intermediary virtual field model that acts as a mediator between the dipper control system and the physical tracks. This virtual field serves as a protective layer that translates spatial proximity into motion constraints, allowing the operator to work freely while the system automatically prevents dangerous movements through the intermediary virtual boundary.
2Reliability
If motion command limits are imposed on the dipper to prevent collisions, then the machinery safety is improved, but the operational flexibility and speed are reduced
Solution Approach 1:
The system applies dynamics by making the motion command limits dynamic rather than static. The virtual fields continuously adapt their constraint strength based on real-time dipper position and proximity to tracks. When the dipper is far from tracks, full motion freedom is allowed; as it approaches, constraints gradually increase, creating a dynamic balance between safety and productivity.
Solution Approach 2:
The patent implements local quality by applying different levels of motion constraints to different spatial zones. The virtual fields create localized protection zones around critical areas like tracks, while allowing unrestricted movement in safe zones. This ensures safety constraints are applied only where and when needed, minimizing impact on overall operational efficiency.
3Object-affected harmful factors
If the dipper is restricted from moving closer to the tracks, then the collision severity is reduced, but the working range and accessibility to mining areas are limited
Solution Approach 1:
The system resolves this contradiction by adding spatial dimensionality through three-dimensional virtual fields. Instead of simple planar restrictions, the virtual fields create volumetric protected zones that account for height, depth, and lateral position. This allows the dipper to access mining areas freely while the system monitors and restricts movement only in the specific dimensional space where collision risk exists.
Data Source
AI summary
Embodiments described herein provide systems and methods for preventing and mitigating collisions between components of an industrial machine. The industrial machine includes an electronic controller, having an electronic processor and a memory, that is configured to receive dipper position data indicative of a position of the dipper and determine a distance between the dipper and tracks of the industrial machine based on the dipper position data. The electronic controller is further configured to set a motion command limit for a dipper motion based on the distance, the dipper motion being selected from a group of a swing motion, a crowd motion, and a hoist motion and control the dipper motion according to a dipper motion command limited by the motion command limit.