The present invention relates to a method for the automated production of a defined face opening for longwall mining operations comprising a face conveyor, a roller cutter loader or disk shearer as an extraction machine, and a hydraulic shield support in underground coal mining.
With the control of longwall mining operations during the extraction work, at stake is generally the best possible utilization of the available machine capacities while avoiding shutdowns, whereby if possible the necessary control processes should be automated in order to prevent incorrect human decisions. Beginnings of an automation of the control can be found in development or already in use, such as recognition/control of interfaces via sensors, learning step processes, recognition and control of the return path of the advancement support, automated advancement of the advancement support and automatic maintenance of a prescribed target inclination of the face conveyor.
One problem with the automation of longwall mining controls includes, among others, being able to ensure that in the forward region of the top canopy of each individual shield support frame, there is an adequate vertical height, in other words, an adequate face opening, in order to ensure that the disk shearer can travel by in a manner free of interference, since each collision of the disk shearer with the top canopy of a shield support frame because of a face opening that is too small leads to corresponding disruptions in operation or even damage to the equipment.
It is therefore an object of the present invention to provide a method of the aforementioned general type that provides indications of a possible collision between the disk shearer and the shield support frame or aids in preventing corresponding collisions.
The realization of this object, including advantageous embodiments and further developments of the invention, results from the content of the patent claims that follow this description.
The invention provides a method wherein the distance between the top or upper edge of the roller or disk base or main body and the bottom side or underside of the slope end cap or top canopy of the shield support below which the main body respectively travels during extraction work, i.e. below which the extraction work takes place, is measured by means of at least one radar sensor mounted on the roller or disk base body of the roller cutter loader or disk shearer, wherein the measured distance is entered into a computer as the actual value of the passage height of the roller cutter loader or disk shearer under the shield support and is then compared to a target value stored in the computer, wherein control commands for adapting the cutting height of at least one of the two cutter rollers or disks of the roller cutting loader or disk shearer are generated if a deviation is determined.
The invention has the advantage that the control objective of maintaining a defined face opening during the extraction travels of the disk shearer can be achieved with a relatively low expenditure. The passage height, which is measured as the distance between the upper edge of the main body of the disk shearer and the underside of the top canopy of the shield support, is also a direct measure for the face opening, since the face opening is composed of the passage height and the distances to the roof or overlying stratum assumed by the longwall equipment, and hence unalterable, on the one hand, and to the footwall or the footwall layer cut free by the footwall disk on the other hand. Thus, the distance to the overlying stratum that goes beyond the passage height is prescribed by the dimensions of the top canopy, while the distance of the radar sensors to the footwall layer is prescribed by the overall height of the face conveyor that rests upon the footwall layer and the main body of the disk shearer that can travel thereon. Thus, the value respectively measured for the passage height is used directly as a synonym for the height of the face opening. The control operations can thus be carried out more rapidly. The target value for the face opening prescribed in the computer is either prescribed by the deposit data, in other words in particular by the thickness of the seam, or is determined by the minimum passage height of the longwall equipment. As a function of the construction data of the longwall equipment, the target value can also be represented as the target travel for the passage opening.
If during the extraction value of the disk shearer it is established that the target value for the passage opening, which for example also contains a safety margin, is not reached or even exceeded, it is possible from the establishment of the deviation to generate control commands that alter or adapt the overall cutting height of the two cutting disks in such a way that the prescribed face opening that is to be maintained is again achieved. A particular advantage relative to the known methods is the short dead control time of only two successive extraction travels, since the face conveyor is then advanced onto the footwall layer that is cut free, and hence with the next passage of the disk shearer, the control result measured at the passage height that is then to be determined can be controlled. This still present dead control time inherently results from the required distance between the cutting disk, the face conveyor, and the radar sensors that are disposed on the main body of the disk shearer that travels on the face conveyor.
Pursuant to one specific embodiment of the invention, the alteration of the cutting height at the conclusion of an extraction travel of the disk shearer is undertaken along the face, so that the conditions during an extraction travel respectively remain constant and are respectively available for comparison purposes.
Alternatively, the alteration of the cutting height of the cutting disks can also be continuously effected as a reaction to the target value deviations detected in the computer; this results in an adaption to position changes of the longwall equipment at any given time.
Pursuant to one exemplary embodiment of the invention, a respective radar sensor is disposed at the additional ends of the main body of the disk shearer, whereby that radar sensor that is respectively toward the front as viewed in the direction of travel delivers the actual signals for the measured distance. Alternatively, the signals received by the two radar sensors can be continuously conveyed to the computer, where they are evaluated, whereby in the event that a deviation of the passage height measured by that radar sensor that is toward the front in the direction of travel from the target value is determined, a control command is immediately generated for the rear cutting disk of the disk shearer as viewed in the direction of travel.
If pursuant to one embodiment of the invention additionally the correction value of the cutting height of the cutting disks established during successive extraction travels by the respectively generated control commands are compared with one another for adjustment purposes, and the total value determined from the correction values is used as a measure for an input convergence and is taken into account with future extraction travels when a necessary cutting height adaptation is determined, it is possible in this manner to draw conclusions regarding a convergence that commences in the meantime. If during a first extraction travel there is a need for correcting the cutting height, it is possible to check for the next extraction travel whether after carrying out the correction the prescribed face opening is cut free. If in so doing a new requirement for correction results, this can be brought about only by a convergence that commences in the meantime.
Pursuant to one embodiment of the invention, the face height determination via the radar measurement is supplemented in that by means of the inclination sensors mounted on at least three of the four main components of each shield support frame, such as floor skid, gob shield, supporting connection rods, and that region on the top canopy of the side of the gob shield, the inclination of the shield support components relative to the horizontal are determined in the direction of advancement, and from the measured data, in a computer, by comparison with base data that is stored therein and that defines the geometrical orientation of the components and their movement during the advancement, the respective perpendicular height of the shield support frame at the front end of the top canopy is calculated as a measure for the actual face opening, and the thus determined actual values of the shield height calculation are conveyed to the computer, which processes the actual values from the passage height measurement. Whereas the radar measurement respectively delivers data only during the passage of the extraction machine below the respective shield support frame, and thus does not recognize a passage height that is too low from the outset and can be taken into account upon the determination of the extraction parameters, the supplemental determination of the face opening by means of the determination of the shield support height has the advantage that the data thus obtained at individual shield support frames provides additional information regarding the condition of individual sections of the face front, or the entire face front as extraction progresses, thus enabling an integral process control of the respective mining operation.
Thus, from the relationship of the calculated and the measured face opening relative to the deposit data applicable for the respective mining operation, such as the seam thickness that possibly changes over the length of the face, right from the start one can deduce whether there exists a danger of hang-ups within the longwall equipment due to the overlying stratum applying load to the shield support frames, or whether there is the threat that the upper adjustment limit of the shield support frame will be exceeded with an aspired-to automatic operation. The danger of getting hung-up exists when, with the commencement of convergence, the shield props are entirely retracted, and due to the fact that the overlying stratum then applies load, the shield frame is blocked and can no longer be moved away; a further possibility is that the steel construction can become blocked at the lower adjustment limit in the lemniscate gear mechanism of the shield support frame, or in the joint top canopy/gob shield, and also then can no longer be moved away. Finally, contact or striking of the top canopy of the shield support frame upon or on the upper edge of the brake of the face conveyor can occur, as a result of which a moving along of the face conveyor and/or an advancement of the shield support frame is similarly prevented or at least hindered to a great extent. The aforesaid moments of danger are particularly applicable when traveling through saddles or troughs in the contour of the seam or bed, which can be taken into account right from the beginning by means of an appropriate setting of the cutting height of the disk shearer. Furthermore, the corresponding face opening data can provide information about a possible caving from the roof or overlying stratum, the occurrence of narrowings of the seam, the “traveling-on-coal” by the disk shearer and/or a possible cutting of the disk shearer into the footwall.
Thus, the determination of the shield height delivers data for the face opening that is to be anticipated, which can then be compared with the data measured from the disk shearer as it passes through. Thus, the precisions of both manners of proceeding can be better estimated. To this extent, the two manners of proceeding complement one another, thus providing a redundancy when checking the respective face opening. A further advantage is that even if one of the two systems for determining the face opening fails, the extraction can continue on the basis of the remaining measurement system.
In this regard, pursuant to another embodiment of the invention, the actual values from the passage height measurement, taking into account the overall height of the top canopy and the construction of the face conveyor and the main body of the disk shearer, are converted into an actual face opening and are compared with the actual face opening as the product of the shield height calculation.
Further to be considered is that the inclination of the cutting disks of the disk shearer relative to the coal face in the direction of mining can have a considerable part in the alteration of the face opening by the cutting work. This inclination results from the fact that with a correction of the cutting height in particular of the footwall disk, traveling over the step that thereby results in the footwall layer leads to a tilting of the face conveyor relative to the footwall or even relative to the overlying stratum upon advancement of the face conveyor in the direction of mining due to the cutting width of the cutting disks, which is less than the width of the face conveyor with the main body of the disk shearer traveling thereon. Thus, with normal geometrical dimensions in the context of longwall equipment utilized these days, at a differential angle between the contour of the seam and the position of the face conveyor in the direction of mining of only 6 gon, there results a face height alteration of up to 100 mm, which can be corrected only in the course of further extraction travels. For this purpose, pursuant to a further development of the invention, the inclination of the face conveyor and/or disk shearer relative to the horizontal in the direction of mining is determined by means of inclination sensors mounted on the face conveyor and/or disk shearer, whereby the angle of inclination of the face conveyor and/or the disk shearer in a relationship to the angle of inclination determined at the top canopy of the shield support frame and/or at the floor skid thereof can be set, and the differential angle formed thereby can be taken into account in the calculation of the actual face opening that is to be established with successively following advancement cycles of the shield support frame. This has the advantage that the character of the face front can on the whole be recognized early, so that by timely counteracting, disadvantageous influences upon the face opening obtained by the mining work can be countered, to the extent that pursuant to one embodiment of the invention the inclination of the cutting disks of the disk shearer in the direction of mining transverse to the direction of cutting, as described by the determined differential angle, is taken into account during the establishment of a necessary cutting height adaptation.
With regard to an apparatus for carrying out the method described above, the radar sensors are set flushly into the surface of the main body of the disk shearer, so that as a result an exact value for the face opening can be measured. In order to respectively ensure the function of the radar sensors, pursuant to one specific embodiment of the invention a high pressure water rinsing device for the radar sensors is arranged on the main body of the disk shearer, and pursuant to a specific embodiment of the invention is time-controlled. Pursuant to an alternative embodiment, the high pressure water rinsing device can be event-controlled, i.e. for example the degree of fouling or dirt-accumulation is recognized, and when the dirt accumulation limits the precision of measurement, activation of the high pressure water rinsing device is effected. Pursuant to an alternative embodiment, for the cleaning of the radar sensors a mechanically operating scraping device can be provided. Here also a time-controlled or event-controlled activation of the scraping device can be provided. To the extent that with the embodiment described above the radar sensors that are disposed in the region of the surface of the main body of the disk shearer are disposed in the main dirt-accumulation region of the main body, to reduce the dirt accumulation alternatively the radar sensors can be disposed laterally on the path of travel side of the main body of the disk shearer, whereby the radar sensors can preferably be provided between the winches that are disposed on the main body of the disk shearer, and hence in a region that is also mechanically protected. With a view toward reducing the dirt accumulation, rather than providing the radar sensors with a “direction of view” that is perpendicularly upwardly relative to the top canopy of the shield support frame, the radar sensors can be disposed at an angle relative to the surface of the main body of the disk shearer, so that the thus inclined surface of the radar sensors is less susceptible to dirt. In the course of the evaluation of the signals received from the radar sensors, in such a case the measured longer path of the radar signals must be converted to a perpendicular distance between the upper edge of the main body of the disk shearer and the underside of the top canopy of the shield support frame.
To increase the precision of measurement, two radar sensors can be disposed on the main body of the disk shearer at a distance from one another and with a beam direction that is opposite to one another; in such a case, both signal transmission durations can be converted into the desired spacing or distance determination, and the distances resulting therefrom can be established in relationship to one another.
Specific embodiments of the invention are shown in the drawing, which is described subsequently and in which:
a-c are side views of the longwall equipment of
As can be seen first of all from
In order to measure the passage height between the upper edge of the main body 14 of the disk shearer and the underside of the top canopy 28 of the pertaining shield support 25 below which the main body travels during the extraction work, in other words below which the extraction work takes place, two radar sensors 18 are disposed on the main body set flushly in the upper surface of the main body 14; the radar sensors 18 emit signals perpendicularly and upwardly in the direction of the top canopies 28, and again receive the reflected signals, so that the distance between the top canopies 28 and the main body 14 can be determined in a straightforward manner, and in particular already early during the extraction travel of the disk shearer 13. In the illustrated embodiment, the two radar sensors 18 are disposed at the front and rear ends of the main body 14 respectively, and are set flushly into the upper surface of the main body. Although not illustrated, appropriate cleaning devices in the form of mechanical scrapers or high pressure water rinsing devices can be provided.
As can be further seen from
If the passage height 22 (
As illustrated in
It can be seen in particular from
Nevertheless, the face height control can be supplemented beyond the use of the radar sensors on the disk shearer 13, and can be checked and improved with respect to its control performance, by additionally carrying out a determination of the actual height of the face opening also in the region of the shield frame support 25. For this purpose, mounted on each shield support frame 25 are inclination sensors, so that it is possible merely on the basis of the geometrical conditions when the shield support frame 25 is used and which can be determined with a relatively small expenditure, to determine the face opening, in the form of the perpendicular height (h1) that exists at the front end of the canopy 28.
As can be seen from
As furthermore indicated in
The features of the subject matter of these documents disclosed in the preceding description, the patent claims, the abstract and the drawings can be important individually as well as in any desired combination with one another for realizing the various embodiments of the invention.
Number | Date | Country | Kind |
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10 2009 030 130.5 | Jun 2009 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2010/003699 | 6/18/2010 | WO | 00 | 12/23/2011 |