Virtual Track Model for Mining Machine Collision Prevention
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Solution Overview
Problem
Mining machines often experience collisions between the dipper and tracks due to operator error, leading to damage, and existing solutions fail to effectively prevent or mitigate these collisions in real-time.
Innovation Solution
A system that generates a three-dimensional virtual track model using data points from the dipper's positions relative to the tracks, allowing for real-time collision prevention by limiting dipper movements based on proximity to the tracks, creating virtual fields that restrict motions as the dipper approaches the tracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the dipper is allowed to move freely along all three motions (hoist, crowd, swing), then the operator has full control and productivity is maintained, but the risk of collision with tracks increases leading to damage
Solution Approach 1:
The system dynamically adjusts dipper motion limits based on real-time position relative to tracks. As the dipper approaches the tracks, the system progressively restricts swing, crowd, and/or hoist motions depending on proximity. This dynamic constraint adjustment prevents collisions while maintaining operational flexibility when safe
Solution Approach 2:
The system continuously monitors dipper position using sensors and compares it against the virtual track model. Based on this feedback, the controller automatically adjusts motion limits in real-time, providing closed-loop control that prevents collision while preserving operator control when safe
2Measurement precision
If a complex virtual track model is created to accurately represent custom tracks of varying sizes, then collision detection precision is improved, but the modeling process becomes time-consuming and complicated
Solution Approach 1:
The system performs preliminary dipper movements to specific positions where data points are collected. These pre-planned movements to known locations enable the electronic processor to extrapolate virtual track boundaries before actual mining operations begin, ensuring accuracy without complex manual modeling
Solution Approach 2:
The system automatically collects data points and generates the virtual track model without requiring complex external input. The electronic processor uses data from dipper position sensors to autonomously extrapolate track boundaries, eliminating the need for complicated manual surveying or complex CAD modeling processes
Data Source
AI summary
Embodiments described herein provide systems and methods for generating a three-dimensional virtual track model. This track model may be used, for example, in collision prevention and mitigation systems and methods, such as those described herein, and in other collision prevention and mitigation systems and other mining systems using virtual track models. In some embodiments, the systems and methods described herein provide a simplified modeling process that enables quick, accurate modeling of tracks of a mining machine that can account for custom tracks that vary in size depending on the particular mining machine.