Reliability and wear resistance of cutting picks play a significant role in coal mine exploitation with coal shearers.Tool bit separation,blade breaking,severe erosion of the cutting body and fatigue fractures are the...Reliability and wear resistance of cutting picks play a significant role in coal mine exploitation with coal shearers.Tool bit separation,blade breaking,severe erosion of the cutting body and fatigue fractures are the main reasons for failure of cutting picks.We carried out carburization on a 30CrMnMo alloy to synthesize a new cutting pick material with improved mechanical properties and high wear resistance.The results indicated that carburization can effectively strengthen the surface of the 30CrMnMo alloy by forming a thick carburized layer and thus significantly improve the surface hardness and wear resistance.In addition,the excellent toughness of 30CrMnMo alloy as a substrate of cutting picks can prevent brittle ruptures and fatigue fractures under high impact stress conditions.The significant decrease in both frictional coefficient and rate of erosion of this carburized 30CrMnMo alloy suggests that this alloy is a potential material for cutting picks of coal shearers after rational carburization.展开更多
The reliability and maintainability of electrical system of drum shearer at Parvade. 1 Coal Mine in central Iran was analyzed. The maintenance and failure data were collected during 19 months of shearer operation. Acc...The reliability and maintainability of electrical system of drum shearer at Parvade. 1 Coal Mine in central Iran was analyzed. The maintenance and failure data were collected during 19 months of shearer operation. According to trend and serial correlation tests, the data were independent and identically distributed （iid） and therefore the statistical techniques were used for modeling. The data analysis show that the time between failures （TBF） and time to repair （TTR） data obey the lognormal and Weibull 3 parameters distribution respectively. Reliability-based preventive maintenance time intervals for electrical system of the drum shearer were calculated with regard to reliability plot. The reliability-based maintenance intervals for 90%, 80%, 70% and 50% reliability level are respectively 9.91, 17.96, 27.56 and 56.1 h. Also the calculations show that time to repair （TTR） of this system varies in range 0.17-4 h with 1.002 h as mean time to repair （MTTR）. There is a 80% chance that the electrical system of shearer of Parvade. 1 mine repair will be accomplished within 1.45 h.展开更多
Longwall mining continues to remain the most efficient method for underground coal recovery. A key aspect in achieving safe and productive longwall mining is to ensure that the shearer is always correctly positioned w...Longwall mining continues to remain the most efficient method for underground coal recovery. A key aspect in achieving safe and productive longwall mining is to ensure that the shearer is always correctly positioned within the coal seam. At present, this machine positioning task is the role of longwall personnel who must simultaneously monitor the longwall coal face and the shearer's cutting drum position to infer the geological trends of the coal seam. This is a labour intensive task which has negative impacts on the consistency and quality of coal production. As a solution to this problem, this paper presents a sensing method to automatically track geological coal seam features on the longwall face, known as marker bands, using thermal infrared imaging. These non-visible marker bands are geological features that link strongly to the horizontal trends present in layered coal seams. Tracking these line-like features allows the generation of a vertical datum that can be used to maintain the shearer in a position for optimal coal extraction. Details on the theory of thermal infrared imaging are given, as well as practical aspects associated with machine-based implementation underground. The feature detection and tracking tasks are given with real measurements to demonstrate the efficacy of the approach. The outcome is important as it represents a new selective mining capability to help address a long-standing limitation in longwall mining operations.展开更多
As the main equipment of coal mining production,the anomaly detection of shearer is important to ensure production efficiency and coal mine safety.One key challenge lies in the limited or even absence of labeled monit...As the main equipment of coal mining production,the anomaly detection of shearer is important to ensure production efficiency and coal mine safety.One key challenge lies in the limited or even absence of labeled monitoring data for the equipment,coupled with the high costs associated with manual annotation.Another challenge stems from the complex structure of the mining machines,making it difficult to reflect the overall operational state through local anomaly detection.Consequently,the application of decoupled local anomaly detection for mining machines in practical production remains challenging.This paper presents an unsupervised learning-based method for detecting anomalies in shearer.The method includes a module for constructing a Multi-scale Correlation Matrix(MSCM)of mining machine operating conditions,as well as the CNN-ConvLSTM Autoencoder(C-CLA)network.The module for constructing an MSCM enhances the representation of interrelationships between various features of the equipment from different perspectives using multiple correlation analysis methods.The C-CLA network integrates convolutional and convolutional recurrent neural networks,with the convolutional structure extracting local spatial features and the ConvLSTM structure further capturing information from different time scales and feature scales,thereby enhancing the model’s perceptual capabilities towards changes in equipment status.Finally,shearer anomaly detection is achieved through the analysis of reconstructed residual matrices.The rationality and practicality of the proposed method have been validated on our dataset,and the model’s generalization capability has been verified through repeated experiments in similar scenarios.However,due to variations in the working environment of different mining faces and differences in equipment models,implementing detection on other mining faces often requires retraining the model with new data.Furthermore,we compared our method with other anomaly detection techniques,and our detection efficiency was superior by approximately 3%.This method effectively detects anomalies in the shearer.展开更多
The authors indicate that the failure of hydraulic systems of shearers can drop greatly, its’ reliability and service life can be increased by the use of a field oil contamination analyser and filter device to contro...The authors indicate that the failure of hydraulic systems of shearers can drop greatly, its’ reliability and service life can be increased by the use of a field oil contamination analyser and filter device to control the oil contamination of the hydraulic systems of shearers. Experimental provement of silting theory contamination analyser are carried out.The filter effect of portable hydraulic driving oil filter model YLJ 21 is examinationed in laboratory and field experiment. From January to August 1992, on site experimental research using a silting theory contamination analyser and oil filter model YLJ 21 to control the oil contamination was carried out in the Datong Coal Mining Bureau.展开更多
This paper reviews the development of U.S. longwall mining from an unknown to became the world standard in the past five decades with emphasis on automation. Large scale longwall face equipment were imported from Germ...This paper reviews the development of U.S. longwall mining from an unknown to became the world standard in the past five decades with emphasis on automation. Large scale longwall face equipment were imported from Germany and United Kingdom to increase production in the 1970 s and great effort was made to improve them to suit U.S. conditions, rather than domestic market. Automation began with the development of electrohydraulic shields in 1984 and continue to present. Introduction of first generation semi-automated longwall system occurred in 1995 and step-to-step improvement continues to present following the development of sensor technology and internet of things(IOT). Since then, emphasis on new development has been concentrated on the improvement of equipment reliability, miner's health and safety as well as production, including dust control techniques, proximity sensor, anti-collision and remote control. Automation is classified into two categories: automation of individual face equipment and automation of longwall system. The automation development of longwall system is divided into three stages: shearer-initiated-shield-advance(SISA), semi-automated longwall system, and remote control shearer.展开更多
Cutting tests were done using a test bed designed to measure pick cutting forces when cutting coal and rock.The test equipment has a drum with two starting helical vanes.Cutting forces on a pick were measured as a fun...Cutting tests were done using a test bed designed to measure pick cutting forces when cutting coal and rock.The test equipment has a drum with two starting helical vanes.Cutting forces on a pick were measured as a function of coal compressive strength,pick carbide tip diameter and the cutting depth per drum revolution.The results show that the cutting force is linearly related to the compressive strength.The relationship between the cutting force and both the carbide tip diameter and the cutting depth are exponential.Fluctuation in the cutting force does not increase with coal compressive strength but it has a linear relationship to tip diameter.A plot of cutting force fluctuations versus the cutting depth follows a sigmoidal curve.Based on the analysis of these test results a theoretical basis is supplied for design and effective use of shearer drums.展开更多
Self-positioning of a shearer is the key technology for mining with a man-less working face. In an underground coal mine all radio navigation; satellite positioning or celestial navigation methods have their limitatio...Self-positioning of a shearer is the key technology for mining with a man-less working face. In an underground coal mine all radio navigation; satellite positioning or celestial navigation methods have their limitations. We analyzed an inertial navi-gation system intended to guide the movement a shearer and designed a self-positioning device for the shearer. Simulation tests were also performed on the system. We analyzed the errors observed in these tests to show that the main reason for the low preci-sion of the self-positioning system is accumulated error in the inertial sensor. A Kalman filtering algorithm used in combination with the shearer motion model effectively reduces the measurement errors of the self-positioning system by compensating for gyroscopic drift. Finally, we built an error compensation model to reduce accumulated errors using continuous correction to provide self-positioning of the shearer within a certain range of accuracy.展开更多
A mathematical hydraulic support self-tracking model for three-machine cooperative mining is proposed to address low efficiency and difficulties in strategy evaluation of a fully mechanized coal face.The proposed mode...A mathematical hydraulic support self-tracking model for three-machine cooperative mining is proposed to address low efficiency and difficulties in strategy evaluation of a fully mechanized coal face.The proposed model uses the coordinates and traction speed of the shearer to calculate the frequency of the circular hydraulic support and realize the coordinated operation of the three-machine mining technology.A unity3d hardware-in-the-loop simulation experimental hearer and hydraulic support platform was used to validate the model of autonomous follow-up.The results indicate that collaborative control of coal mining allowed for an efficiency 3.76%higher than under automatic operation mode and 46.03%higher than under manual control;thus,The mathematical model provided an improved production efficiency of the fully mechanized mining face.The mathematical model also provides a more intelligent and reliable security support,and improves the intelligent level of hydraulic support follow-up control.展开更多
An intelligent shearer height adjusting system is a key technology for mining at a man-less working face.A control strategy for a shearer height adjusting system based on a mathematical model of the height adjusting m...An intelligent shearer height adjusting system is a key technology for mining at a man-less working face.A control strategy for a shearer height adjusting system based on a mathematical model of the height adjusting mechanism is proposed.It considers the non-linearity and time variations in the control process and uses Dynamic Fuzzy Neural Networks(D-FNN).The inverse characteristics of the system are studied.An adaptive on-line learning and error compensation mechanism guarantees sys-tem real-time performance and reliability.Parameters from a German Eickhoff SL500 shearer were used with Maflab/Simulink to simulate a height adjusting control system.Simulation shows that the trace error of a D-FNN controller is smaller than that of a PID controller.Also,the D-FNN control scheme has good generalization and tracking performance,which allow it to satisfy the needs of a shearer height adjusting system.展开更多
The hydraulic system plays an important role in supplying power and its transition to other working parts of a coal shearer machine. In this paper, the reliability of the hydraulic system of a drum shearer was analyze...The hydraulic system plays an important role in supplying power and its transition to other working parts of a coal shearer machine. In this paper, the reliability of the hydraulic system of a drum shearer was analyzed. A case study was done in the Tabas Coal Mine in Iran for failure data collection. The results of the statistical analysis show that the time between failures （TBF） data of this system followed the 3-parameters Weibull distribution. There is about a 54% chance that the hydraulic system of the drum shearer will not fail for the first 50 h of operation. The developed model shows that the reliability of the hydraulic system reduces to a zero value after approximately 1 650 hours of operation. The failure rate of this system decreases when time increases. Therefore, corrective maintenance （run-to-t^ailure） was selected as the best maintenance strategy for it.展开更多
To solve the problem of a low coal-loading rate being exhibited by the drum shearer on Chinese thin coal seams,systematic tests and research were performed to study the pivotal factors’influences on drum coal-loading...To solve the problem of a low coal-loading rate being exhibited by the drum shearer on Chinese thin coal seams,systematic tests and research were performed to study the pivotal factors’influences on drum coal-loading rate using a model test method.The effects of the drum hub diameter,cutting depth,vane helix angle,drum rotation speed and hauling speed on drum coal-loading rate were determined under circumstances of coal-loading with drum ejection and pushing modes,and reasons for these phenomena were analyzed.The results indicate that the influence of the drum cutting depth on the drum coal-loading rate is the most significant.The parameters of hub diameter,drum rotation speed and hauling speed can influence the drum coal-loading rate by cutting the coals’filling rate in the drum.The parameters of vane helix angle and drum rotation speed can influence drum coal-loading rates by influencing the ratio of cutting coals’tangential and axial speed in the drum.The coal-loading rate with drum ejection is clearly higher than that observed with drum pushing.Research in this study can provide support to design the drum structure and select drum operational parameters for a thin coal seam shearer.展开更多
Oblique cutting is a working condition in fully mechanized mining whose function is making it possible for coal shearer to cut coal wall.Coal shearer often exhibit large vibration amplitudes in oblique cutting since t...Oblique cutting is a working condition in fully mechanized mining whose function is making it possible for coal shearer to cut coal wall.Coal shearer often exhibit large vibration amplitudes in oblique cutting since the shearer is forced to be bent.In this study,dynamic behavior in oblique cutting for the coal shearer cutting unit gearbox(SCUG)is investigated experimentally based on National Coal Mining Equipment Laboratory of China.A new long wall mining test set-up consists of a test coal shearer and other auxiliary machines is developed for operating long wall coal mining process.Realistic oblique cutting process is developed,and vibration response will be more accurate since both cutting loads and test machine in this experiment are realistic.A data-acquisition system consisting of sensors,channel conditioner and computer is developed to capture three-dimensional vibratory accelerations.A test matrix which included various combinations of key cutting load parameters is executed under realistic oblique cutting loads within a wide parameter range to establish database.Experimental data is analyzed in time,domain and time-frequency domains for investigating the rules of dynamic behavior for SCUG.Beat vibration phenomenon and the coupling of gear mesh frequencies are found in experiment,resulting in local resonance and reduce fatigue life of SCUG.The influence of cutting load on beat phenomenon and frequency coupling is demonstrated at the end,and some conclusions are obtained.展开更多
Underground coal mining frequently uses longwalls.The occurrence of a potentially explosive mixture of methane and air is one of the most serious hazards.A large number of papers have applied numerical modeling of met...Underground coal mining frequently uses longwalls.The occurrence of a potentially explosive mixture of methane and air is one of the most serious hazards.A large number of papers have applied numerical modeling of methane propagation in research aimed at this problem.To date,none of the CFD simulations has considered the movement of the shearer in the analyses.This paper proposes an adaptation of a method used for the description of the movement of trains in tunnels to a specific geometry of a longwall district.The flow of the air-methane mixture was calculated using the finite volume method,in particular the k-w SST and SAS turbulence models.Due to the movement of the shearer,moving and deforming meshes were used for simulation of unsteady flows.Examples of solutions for two hypothetical cases are presented.Finally,the drawbacks and advantages of presented methods are discussed.Further development with the application of either local mesh variability or overset meshes is outlined.展开更多
The double drum coal shearer is widely applied for the underground coal exploration in the mining industry.The vibration and noise control are significant factors for the stability design of the double drum coal shear...The double drum coal shearer is widely applied for the underground coal exploration in the mining industry.The vibration and noise control are significant factors for the stability design of the double drum coal shearer.In this paper,the vibration properties of a double drum coal shearer are firstly investigated.The horizontal,transverse and torsional vibrations of the motor body and the angle displacements of the rockers are taken into account.The walking units and the hydraulic units are modeled by the stiffness-damping systems.The nonlinear equation of motion of the double drum coal shearer is established by applying the Lagrange’s equation.The nonlinear vibration response of the system is calculated by using the Runge Kutta numerical method.The effects of the shearing loads,the equivalent damping and stiffness of the walking units,the inclination angels of the rockers and the equivalent damping and stiffness of the hydraulic units on the vibration properties of the system are discussed.展开更多
Three drums with different helical angles （15°, 20°, and 25°） were developed to investigate improved loading performance of the shearer drum. Nine trials were performed at different drum rotation spee...Three drums with different helical angles （15°, 20°, and 25°） were developed to investigate improved loading performance of the shearer drum. Nine trials were performed at different drum rotation speeds （80, 100, and 120 r/min） and different haulage speeds （1.5, 2.0, and 2.5 m/min） in an orthogonal test design. Loaded coal quantity and cutting power of the drum were the responses measured under the dif- ferent conditions. The effect of the parameters was determined by means of the extreme difference method. The significance of the effects was determined by analysis of variance. The results indicate that the effect from changes in the helical vane on loading performance of the drum is the largest in magnitude. The haulage speed has the least affect on loading performance. The helical angle has the least affect on cutting power of the drum. Haulage speed has the largest affect on the cutting power of the drum. 2011 Published by Elsevier B.V. on behalf of China University of Mining ＆ Technology.展开更多
The impact of the load on the shearer is mainly transmitted through cutting part.In this paper,in order to get the vertical steering vibration characteristics of the cutting part of the drum shearer,the working condit...The impact of the load on the shearer is mainly transmitted through cutting part.In this paper,in order to get the vertical steering vibration characteristics of the cutting part of the drum shearer,the working condition of coal mining machine is simplified.A simplified vertical steering model and the simplified vibration model of the whole cutting part of shearer are established.The vertical steering vibration process of the cutting unit is simplified into a single freedom and one forced vibration system under harmonic excitation.The dynamic response of the cutting part under sine excitation is obtained by using Matlab/Simulink for modeling and simulation.The influence of the support rigidity and damping of the high oil cylinder on the vertical steering vibration characteristics of the cutting part is analyzed.The results show that the damping of the cylinder can reduce the vibration of the system and the stability of the swing process of cutting the part is improved.展开更多
Based on computer graphics principle, technology and 3D graphics software, this paper deals with the 3D part design, assembly and animation of shearer in longwall integrated mechanized coal mining. The matixes of kine...Based on computer graphics principle, technology and 3D graphics software, this paper deals with the 3D part design, assembly and animation of shearer in longwall integrated mechanized coal mining. The matixes of kinetic and geometry relationships and 3 dimension space coordinate systems are built for the cut drums, arms and shearer body. The methods of 3D modeling, dynamic simulation and relative technique problems are discussed.展开更多
In order to determine the influence of shearer's cutting and neighboring shields' advance on the support resistance variation, leg pressure data of all 235 shields in the panel LW61 of Cumberland coal mine wer...In order to determine the influence of shearer's cutting and neighboring shields' advance on the support resistance variation, leg pressure data of all 235 shields in the panel LW61 of Cumberland coal mine were analyzed. The results show that the relationship between the leg pressure increment and the distance from shield to front drum of shearer is a quadratic function and that the higher leg pressure increment before shield advance tends to be related to adverse roof conditions. In addition, the three proposed leg pressure increment-related parameters and the three traditional parameters(time-weighted average pressure, setting pressure, and final pressure) of approximately 32000 shield supporting cycles were calculated by a self-developed software package to analyze the correlation between them. The results show that there is a powerful connection between them, and that the three proposed leg pressure increment-related parameters could be used as the indexes to evaluate the interaction between shields and the roof, and to identify the periodic weighting.展开更多
The pressure signal in the lifting cylinder of the shearer is selected as feature signal, its mean-square deviation is extracted as the feature variable in this paper. The authors put forward a new method of recognizi...The pressure signal in the lifting cylinder of the shearer is selected as feature signal, its mean-square deviation is extracted as the feature variable in this paper. The authors put forward a new method of recognizing the shearer’s cutting state based on pattern recognition. According to this, the completed controI software produced a satisfactory experiment result on the artificial longwall face in the laboratory, Finally the authors look forward to the prospect of the introduction of the artificial neural network theory into this field.展开更多
基金the Youth Foundation of China University of Mining & Technology (No.2009A056)the Tribology Science Fund from State Key Laboratory of Tribology at Tsinghua University (No.SKLTKF08A01)+1 种基金the National Natural Science Foundation of China (Nos.50905180 and 51005234)the National Science and Technology Pillar Program in the Eleventh Five-Year Plan Period (No.2008BAB36B02)
文摘Reliability and wear resistance of cutting picks play a significant role in coal mine exploitation with coal shearers.Tool bit separation,blade breaking,severe erosion of the cutting body and fatigue fractures are the main reasons for failure of cutting picks.We carried out carburization on a 30CrMnMo alloy to synthesize a new cutting pick material with improved mechanical properties and high wear resistance.The results indicated that carburization can effectively strengthen the surface of the 30CrMnMo alloy by forming a thick carburized layer and thus significantly improve the surface hardness and wear resistance.In addition,the excellent toughness of 30CrMnMo alloy as a substrate of cutting picks can prevent brittle ruptures and fatigue fractures under high impact stress conditions.The significant decrease in both frictional coefficient and rate of erosion of this carburized 30CrMnMo alloy suggests that this alloy is a potential material for cutting picks of coal shearers after rational carburization.
文摘The reliability and maintainability of electrical system of drum shearer at Parvade. 1 Coal Mine in central Iran was analyzed. The maintenance and failure data were collected during 19 months of shearer operation. According to trend and serial correlation tests, the data were independent and identically distributed （iid） and therefore the statistical techniques were used for modeling. The data analysis show that the time between failures （TBF） and time to repair （TTR） data obey the lognormal and Weibull 3 parameters distribution respectively. Reliability-based preventive maintenance time intervals for electrical system of the drum shearer were calculated with regard to reliability plot. The reliability-based maintenance intervals for 90%, 80%, 70% and 50% reliability level are respectively 9.91, 17.96, 27.56 and 56.1 h. Also the calculations show that time to repair （TTR） of this system varies in range 0.17-4 h with 1.002 h as mean time to repair （MTTR）. There is a 80% chance that the electrical system of shearer of Parvade. 1 mine repair will be accomplished within 1.45 h.
基金the Australian Coal Association Research Program(ACARP)for their invaluable support that enabled new research and development into longwall shearer automation
文摘Longwall mining continues to remain the most efficient method for underground coal recovery. A key aspect in achieving safe and productive longwall mining is to ensure that the shearer is always correctly positioned within the coal seam. At present, this machine positioning task is the role of longwall personnel who must simultaneously monitor the longwall coal face and the shearer's cutting drum position to infer the geological trends of the coal seam. This is a labour intensive task which has negative impacts on the consistency and quality of coal production. As a solution to this problem, this paper presents a sensing method to automatically track geological coal seam features on the longwall face, known as marker bands, using thermal infrared imaging. These non-visible marker bands are geological features that link strongly to the horizontal trends present in layered coal seams. Tracking these line-like features allows the generation of a vertical datum that can be used to maintain the shearer in a position for optimal coal extraction. Details on the theory of thermal infrared imaging are given, as well as practical aspects associated with machine-based implementation underground. The feature detection and tracking tasks are given with real measurements to demonstrate the efficacy of the approach. The outcome is important as it represents a new selective mining capability to help address a long-standing limitation in longwall mining operations.
文摘As the main equipment of coal mining production,the anomaly detection of shearer is important to ensure production efficiency and coal mine safety.One key challenge lies in the limited or even absence of labeled monitoring data for the equipment,coupled with the high costs associated with manual annotation.Another challenge stems from the complex structure of the mining machines,making it difficult to reflect the overall operational state through local anomaly detection.Consequently,the application of decoupled local anomaly detection for mining machines in practical production remains challenging.This paper presents an unsupervised learning-based method for detecting anomalies in shearer.The method includes a module for constructing a Multi-scale Correlation Matrix(MSCM)of mining machine operating conditions,as well as the CNN-ConvLSTM Autoencoder(C-CLA)network.The module for constructing an MSCM enhances the representation of interrelationships between various features of the equipment from different perspectives using multiple correlation analysis methods.The C-CLA network integrates convolutional and convolutional recurrent neural networks,with the convolutional structure extracting local spatial features and the ConvLSTM structure further capturing information from different time scales and feature scales,thereby enhancing the model’s perceptual capabilities towards changes in equipment status.Finally,shearer anomaly detection is achieved through the analysis of reconstructed residual matrices.The rationality and practicality of the proposed method have been validated on our dataset,and the model’s generalization capability has been verified through repeated experiments in similar scenarios.However,due to variations in the working environment of different mining faces and differences in equipment models,implementing detection on other mining faces often requires retraining the model with new data.Furthermore,we compared our method with other anomaly detection techniques,and our detection efficiency was superior by approximately 3%.This method effectively detects anomalies in the shearer.
文摘The authors indicate that the failure of hydraulic systems of shearers can drop greatly, its’ reliability and service life can be increased by the use of a field oil contamination analyser and filter device to control the oil contamination of the hydraulic systems of shearers. Experimental provement of silting theory contamination analyser are carried out.The filter effect of portable hydraulic driving oil filter model YLJ 21 is examinationed in laboratory and field experiment. From January to August 1992, on site experimental research using a silting theory contamination analyser and oil filter model YLJ 21 to control the oil contamination was carried out in the Datong Coal Mining Bureau.
基金provided by the National Key R&D Program of China (No. 2017YFC060300204)the National Natural Science Foundation of China (Nos. 51604267 and 51704095)+1 种基金Yue Qi Young Scholar Project CUMTBYue Qi Distinguished Scholar Project (No. 800015Z1138)
文摘This paper reviews the development of U.S. longwall mining from an unknown to became the world standard in the past five decades with emphasis on automation. Large scale longwall face equipment were imported from Germany and United Kingdom to increase production in the 1970 s and great effort was made to improve them to suit U.S. conditions, rather than domestic market. Automation began with the development of electrohydraulic shields in 1984 and continue to present. Introduction of first generation semi-automated longwall system occurred in 1995 and step-to-step improvement continues to present following the development of sensor technology and internet of things(IOT). Since then, emphasis on new development has been concentrated on the improvement of equipment reliability, miner's health and safety as well as production, including dust control techniques, proximity sensor, anti-collision and remote control. Automation is classified into two categories: automation of individual face equipment and automation of longwall system. The automation development of longwall system is divided into three stages: shearer-initiated-shield-advance(SISA), semi-automated longwall system, and remote control shearer.
基金Projects 2008AA062202 supported by the Hi-tech Research and Development Program of ChinaCX08B_041Z by the Innovation Foundation of Jiangsu Graduate Students
文摘Cutting tests were done using a test bed designed to measure pick cutting forces when cutting coal and rock.The test equipment has a drum with two starting helical vanes.Cutting forces on a pick were measured as a function of coal compressive strength,pick carbide tip diameter and the cutting depth per drum revolution.The results show that the cutting force is linearly related to the compressive strength.The relationship between the cutting force and both the carbide tip diameter and the cutting depth are exponential.Fluctuation in the cutting force does not increase with coal compressive strength but it has a linear relationship to tip diameter.A plot of cutting force fluctuations versus the cutting depth follows a sigmoidal curve.Based on the analysis of these test results a theoretical basis is supplied for design and effective use of shearer drums.
基金Financial support for this work, provided by the National Natural Science Foundation of China (No.50504014), is gratefully acknowledged
文摘Self-positioning of a shearer is the key technology for mining with a man-less working face. In an underground coal mine all radio navigation; satellite positioning or celestial navigation methods have their limitations. We analyzed an inertial navi-gation system intended to guide the movement a shearer and designed a self-positioning device for the shearer. Simulation tests were also performed on the system. We analyzed the errors observed in these tests to show that the main reason for the low preci-sion of the self-positioning system is accumulated error in the inertial sensor. A Kalman filtering algorithm used in combination with the shearer motion model effectively reduces the measurement errors of the self-positioning system by compensating for gyroscopic drift. Finally, we built an error compensation model to reduce accumulated errors using continuous correction to provide self-positioning of the shearer within a certain range of accuracy.
基金This work was supported by the Project funded by China Postdoctoral Science Foundation under Grant 2019M651081the Merit Funding for the Returned Overseas Personnel Sci-Tech Activities of Shanxi Province under Grant 2016 and Key Research and Development Program of Shanxi(2019)and Innovation Programs of Higher Education Institutions in Shanxi(2019L0305).
文摘A mathematical hydraulic support self-tracking model for three-machine cooperative mining is proposed to address low efficiency and difficulties in strategy evaluation of a fully mechanized coal face.The proposed model uses the coordinates and traction speed of the shearer to calculate the frequency of the circular hydraulic support and realize the coordinated operation of the three-machine mining technology.A unity3d hardware-in-the-loop simulation experimental hearer and hydraulic support platform was used to validate the model of autonomous follow-up.The results indicate that collaborative control of coal mining allowed for an efficiency 3.76%higher than under automatic operation mode and 46.03%higher than under manual control;thus,The mathematical model provided an improved production efficiency of the fully mechanized mining face.The mathematical model also provides a more intelligent and reliable security support,and improves the intelligent level of hydraulic support follow-up control.
基金support for this work,provided by the National High Technology Research and Development Program of China(No2008AA062202)China University of Mining&Technology Scaling Program
文摘An intelligent shearer height adjusting system is a key technology for mining at a man-less working face.A control strategy for a shearer height adjusting system based on a mathematical model of the height adjusting mechanism is proposed.It considers the non-linearity and time variations in the control process and uses Dynamic Fuzzy Neural Networks(D-FNN).The inverse characteristics of the system are studied.An adaptive on-line learning and error compensation mechanism guarantees sys-tem real-time performance and reliability.Parameters from a German Eickhoff SL500 shearer were used with Maflab/Simulink to simulate a height adjusting control system.Simulation shows that the trace error of a D-FNN controller is smaller than that of a PID controller.Also,the D-FNN control scheme has good generalization and tracking performance,which allow it to satisfy the needs of a shearer height adjusting system.
文摘The hydraulic system plays an important role in supplying power and its transition to other working parts of a coal shearer machine. In this paper, the reliability of the hydraulic system of a drum shearer was analyzed. A case study was done in the Tabas Coal Mine in Iran for failure data collection. The results of the statistical analysis show that the time between failures （TBF） data of this system followed the 3-parameters Weibull distribution. There is about a 54% chance that the hydraulic system of the drum shearer will not fail for the first 50 h of operation. The developed model shows that the reliability of the hydraulic system reduces to a zero value after approximately 1 650 hours of operation. The failure rate of this system decreases when time increases. Therefore, corrective maintenance （run-to-t^ailure） was selected as the best maintenance strategy for it.
基金Project(2012AA062104)supported by the National High Technology Research and Development Program of ChinaProject(51704178)supported by the National Natural Science Foundation of China+1 种基金Project(ZR2017MEE034)supported by Natural Science Foundation of Shandong Province,ChinaProject(2018T110700)supported by China Postdoctoral Science Foundation
文摘To solve the problem of a low coal-loading rate being exhibited by the drum shearer on Chinese thin coal seams,systematic tests and research were performed to study the pivotal factors’influences on drum coal-loading rate using a model test method.The effects of the drum hub diameter,cutting depth,vane helix angle,drum rotation speed and hauling speed on drum coal-loading rate were determined under circumstances of coal-loading with drum ejection and pushing modes,and reasons for these phenomena were analyzed.The results indicate that the influence of the drum cutting depth on the drum coal-loading rate is the most significant.The parameters of hub diameter,drum rotation speed and hauling speed can influence the drum coal-loading rate by cutting the coals’filling rate in the drum.The parameters of vane helix angle and drum rotation speed can influence drum coal-loading rates by influencing the ratio of cutting coals’tangential and axial speed in the drum.The coal-loading rate with drum ejection is clearly higher than that observed with drum pushing.Research in this study can provide support to design the drum structure and select drum operational parameters for a thin coal seam shearer.
基金This paper was supported by the National Basic Research Program of China(2014CB046303).
文摘Oblique cutting is a working condition in fully mechanized mining whose function is making it possible for coal shearer to cut coal wall.Coal shearer often exhibit large vibration amplitudes in oblique cutting since the shearer is forced to be bent.In this study,dynamic behavior in oblique cutting for the coal shearer cutting unit gearbox(SCUG)is investigated experimentally based on National Coal Mining Equipment Laboratory of China.A new long wall mining test set-up consists of a test coal shearer and other auxiliary machines is developed for operating long wall coal mining process.Realistic oblique cutting process is developed,and vibration response will be more accurate since both cutting loads and test machine in this experiment are realistic.A data-acquisition system consisting of sensors,channel conditioner and computer is developed to capture three-dimensional vibratory accelerations.A test matrix which included various combinations of key cutting load parameters is executed under realistic oblique cutting loads within a wide parameter range to establish database.Experimental data is analyzed in time,domain and time-frequency domains for investigating the rules of dynamic behavior for SCUG.Beat vibration phenomenon and the coupling of gear mesh frequencies are found in experiment,resulting in local resonance and reduce fatigue life of SCUG.The influence of cutting load on beat phenomenon and frequency coupling is demonstrated at the end,and some conclusions are obtained.
基金The results presented in this paper are the result of the PICTO research project titled"Production Face Environmental Risk Minimization in Coal and Lignite Mines”,No.800711,financed by the Research Programme of the Research Fund for Coal and Steel(RFCS)and Polish MNiSW No W93/FBWiS/2018 and the statutory research funds of the Institute.
文摘Underground coal mining frequently uses longwalls.The occurrence of a potentially explosive mixture of methane and air is one of the most serious hazards.A large number of papers have applied numerical modeling of methane propagation in research aimed at this problem.To date,none of the CFD simulations has considered the movement of the shearer in the analyses.This paper proposes an adaptation of a method used for the description of the movement of trains in tunnels to a specific geometry of a longwall district.The flow of the air-methane mixture was calculated using the finite volume method,in particular the k-w SST and SAS turbulence models.Due to the movement of the shearer,moving and deforming meshes were used for simulation of unsteady flows.Examples of solutions for two hypothetical cases are presented.Finally,the drawbacks and advantages of presented methods are discussed.Further development with the application of either local mesh variability or overset meshes is outlined.
基金Projects(51975511,U1708254)supported by the National Natural Science Foundation of ChinaProject(N2003023)supported by the Fundamental Research Funds for the Central Universities of China+1 种基金Project(2019YFB2004400)supported by the National Key Research and Development Program of ChinaProject(2020-MS-092)supported by the Natural Science Foundation of Liaoning Province,China。
文摘The double drum coal shearer is widely applied for the underground coal exploration in the mining industry.The vibration and noise control are significant factors for the stability design of the double drum coal shearer.In this paper,the vibration properties of a double drum coal shearer are firstly investigated.The horizontal,transverse and torsional vibrations of the motor body and the angle displacements of the rockers are taken into account.The walking units and the hydraulic units are modeled by the stiffness-damping systems.The nonlinear equation of motion of the double drum coal shearer is established by applying the Lagrange’s equation.The nonlinear vibration response of the system is calculated by using the Runge Kutta numerical method.The effects of the shearing loads,the equivalent damping and stiffness of the walking units,the inclination angels of the rockers and the equivalent damping and stiffness of the hydraulic units on the vibration properties of the system are discussed.
基金support for this work was provided by the National Natural Science Foundation of China (No. 51005232)the China Postdoctoral Science Foundation (No. 20100481176)
文摘Three drums with different helical angles （15°, 20°, and 25°） were developed to investigate improved loading performance of the shearer drum. Nine trials were performed at different drum rotation speeds （80, 100, and 120 r/min） and different haulage speeds （1.5, 2.0, and 2.5 m/min） in an orthogonal test design. Loaded coal quantity and cutting power of the drum were the responses measured under the dif- ferent conditions. The effect of the parameters was determined by means of the extreme difference method. The significance of the effects was determined by analysis of variance. The results indicate that the effect from changes in the helical vane on loading performance of the drum is the largest in magnitude. The haulage speed has the least affect on loading performance. The helical angle has the least affect on cutting power of the drum. Haulage speed has the largest affect on the cutting power of the drum. 2011 Published by Elsevier B.V. on behalf of China University of Mining ＆ Technology.
基金Project (BK20160250) supported by the Natural Science Foundation of Jiangsu Province,ChinaProject (17XLR028) supported by the Natural Science Foundation of Jiangsu Normal University,China
文摘The impact of the load on the shearer is mainly transmitted through cutting part.In this paper,in order to get the vertical steering vibration characteristics of the cutting part of the drum shearer,the working condition of coal mining machine is simplified.A simplified vertical steering model and the simplified vibration model of the whole cutting part of shearer are established.The vertical steering vibration process of the cutting unit is simplified into a single freedom and one forced vibration system under harmonic excitation.The dynamic response of the cutting part under sine excitation is obtained by using Matlab/Simulink for modeling and simulation.The influence of the support rigidity and damping of the high oil cylinder on the vertical steering vibration characteristics of the cutting part is analyzed.The results show that the damping of the cylinder can reduce the vibration of the system and the stability of the swing process of cutting the part is improved.
文摘Based on computer graphics principle, technology and 3D graphics software, this paper deals with the 3D part design, assembly and animation of shearer in longwall integrated mechanized coal mining. The matixes of kinetic and geometry relationships and 3 dimension space coordinate systems are built for the cut drums, arms and shearer body. The methods of 3D modeling, dynamic simulation and relative technique problems are discussed.
基金provided by the National High Technology Research and Development Program of China(No.2012AA062100)the Program for New Century Excellent Talents in University of China(No.NCET-10-0770)
文摘In order to determine the influence of shearer's cutting and neighboring shields' advance on the support resistance variation, leg pressure data of all 235 shields in the panel LW61 of Cumberland coal mine were analyzed. The results show that the relationship between the leg pressure increment and the distance from shield to front drum of shearer is a quadratic function and that the higher leg pressure increment before shield advance tends to be related to adverse roof conditions. In addition, the three proposed leg pressure increment-related parameters and the three traditional parameters(time-weighted average pressure, setting pressure, and final pressure) of approximately 32000 shield supporting cycles were calculated by a self-developed software package to analyze the correlation between them. The results show that there is a powerful connection between them, and that the three proposed leg pressure increment-related parameters could be used as the indexes to evaluate the interaction between shields and the roof, and to identify the periodic weighting.
文摘The pressure signal in the lifting cylinder of the shearer is selected as feature signal, its mean-square deviation is extracted as the feature variable in this paper. The authors put forward a new method of recognizing the shearer’s cutting state based on pattern recognition. According to this, the completed controI software produced a satisfactory experiment result on the artificial longwall face in the laboratory, Finally the authors look forward to the prospect of the introduction of the artificial neural network theory into this field.
