文昌校区-倪艳笑-学术写作7班-JB16020004-唐杰兵-2016.12

Prospects of intelligent synthesis mechanization on roadway drivage operation line

Abstract

The paper describes the state-of-the-art drivage line and intelligent roadheader by 12 aspects from home and abroad in the drift of coal mine.

INTRODUCTION

Roadway drivage of coal mining often faces numbers of arduous tasks and very complicated hazards-coal and gas outburst, rock burst, bursting water, obstructed view and noise etc., not to mention that the coal companies only focus on the efficiency of production. In light of those difficults, some coal mining equipment companies including a batch of the scientific personnel have been committed to improving the roadway drivage opration line.Particularly,lots of relatived theories and in-field instructive practices have been emerged in recent decade.The representative projects comprise of Europe’s ADRIS and NEMAQ（2007-2010）(Dr. J. Czwalinna, 2011)(Dr. Samir NABUSLI, 2012),Poland’s KOMAG (in collaboration with Silesian University) (Świder & Jasiulek, 2009),Australia’s CSIRO(Reid, 2010) and China’s“863/973 projects”(1-7) (Zhongguo, 2016),etc. These new system enhances safety in the mining operation, betters the miners’ working conditions, improves the quality of the extracted roadway, and increases drifting footage. This paper elaborates twelve aspects of the main achievements of the advanced drivage and intelligent roadheader at home and abroad.

1．the optimization of drum

The cutter picks’ strength has dramatically improved along with their stiffness and abrasive resistance. The new cutting tip materials namely PCD, Polycrystalline diamond composites has been used to to overcome the problem of premature failure. The application of the code simulation has largely shorten the research cycles as well as the expensive cost of blindfold test. These simulations have been used to correlate rock properties with pick forces, to study dust make and cutter wear and to simulate the interaction of picks on rotary machines. The experimented processes have been carried out purposefully and intentionally, such as in RAG, Sandvik and Ekhof etc. With these efforts, we have fulfilled a significant progress(8, 9) consist of torsional vibration cutting technique, High pressure water assisted cutting technique , Circular cutting knife, Vibrating disc knife and shock vibration technique etc., in which part of them have been applied on-sites but others are still testing. Building on its transformational DynaCut (Ostillating Disc Cutter, ODC)rock breaking technology, Joy Global has increased cutting rates by a factor of 10(10).

2.the identifying of coal and rock

Using the kinematics of the machine, Fraunhofer IML developed a 3D laser scanner system(as shown in Fig.2-1) scanning the heading face within the infrared spectrum. An integrated signal processor calculates the coordinates of the coal seam and transfers them to the control of the machine, which determines the ideal value for the next step of excavation(11). By turning the cutter boom in a horizontal way the scanners are able to sample the whole face in a 3D-manner.Such technique(12-14) include Infrared LADAR Imaging, Thermal imaging and shear fitting technique imaging,etc. The concept of virtual prototyping of a roadheader’s control system consisting in coupling the real PLC controller, made by WAGO, with the virtual machine with its surrounding was presented(Science, Yanjin, & Jianguang, 2015),in which simulation tests results will enable to verify the control procedures and the proper preparation to be carried out in mine underground. A laser transmitter (Yun, 2015)on the body of boom-type roadheader transmits the revolving laser planes, laser receivers installed behind the boom-type roadheader get the position of laser transmitters through laser planes, then obtain the position and attitude of boom-type roadheader in the roadway coordination frame constructed by laser receives. The approximate iterative method of MATLAB simulation(Hang, Shurong, & Jun, 2015) has been utilized to improve the forming accuracy including trapezoidal, circular arch or non rectangular section greatly and controlled within 1mm(15).

Fig.2-1 Position of the 2D-Laser scanners on the roadheader

3.the precise location and adjustment

The author put forward the specific control methods of pitch attitude compensation control and cutting boundary compensation control(Du, Zhang, Wang, Liu, & Wu, 2013). The Silesian University of Technology carried out a comprehensive range of on-site tests (Zhang, Zhang, & Xu, n.d.) to recognize the adapted advanced control algorithms, cutting resistance of mined rock and the cutter jib angular speed etc. Jia,Wenhao put forward a position and orientation measurement method of single-station, multipoint and time-sharing based on iGPS to locate roadheader body precisely(listing the other 3 methods) (16, 17).

As shown in Fig.3-1, The roadheader has been equipped with the sensors of the vertical and horizontal position of the cutter jib, a sensor of the loading table position, vibration sensors installed on the cutter head, an inclinometer to determine the position of the whole machine as well as with pressure sensors the hydraulic actuators.

Li,Jiangang and Mao jun conducted tracking control of automation roadheader by means of control mechanism and robust neural network to profile memory cutting(18).Using inverse transform and classic elimination theory, the kinematics of jumbolter mounted upon roadheader was precisely located(19).

Fig.3-1 Sensor installation set of the R-130 roadheader

a,b)Jib position sensor;c)Vibrations sensor;d)Loading table sensor;

e)Hydraulic pressure sensor;and f)Inclinometer

4.the reliable sensor and the date-processing method

By using the automatic positioning technology of the boring machine, the roadheader can automatically adjust the running mechanism,which is always in the ideal position of the design requirements of the roadway. As shown in Fig.4-1, total station, gyroscope, electronic compass, laser guiding instrument and visual measurement equipment and system are the main methods used in the current position and orientation(Maidl, Thewes, & Maidl, 2013). In the system infrared sensor with active illumination is applied to improve the reliability of positioning of the roadheader in the absence of visual control of the operator(Roman, Josif, & Nikolay, 2015). In the field implementation of the proposed solution wireless data communication enabled by ZigBee-based wireless sensor networks to collect the remote control real-time surveying results(Shen, Lu, Fernando, & AbouRizk, 2012). A multilayer perceptron(20) (MLP,analogy method of Artificial Neural Network) is a feed forward artificial neural network model that maps sets of input data onto a set of appropriate outputs (Jasiulek, Stankiewicz, & Street, 2011).

Fig.4-1 Different Sensors

5.the assisted parallel operation anchoring and the work face support

A patented laser light grid system has been developed by J.H. Fletcher and Monitech, a South African Company, to aid in proper machine positioning in the heading and proper bolt spacing(21). A kinematics model of 7 degree of freedom driving and anchor machine under the influence of roadheader pose were first established based on the D-H parametric method(Steiner, 2016).The jumbolter location was treated as known measurement.Using inverse transform and classic elimination theory,the inverse kinematics of whole machine was analyzed,as shown in Fig.5-1,5-2．

Fig.5-1 Dual arm concept design:a)Complete model;b)Jumbo arm;c)Miner arm.

Fig.5-2 Sensor functions of the drill boom control system;

Atlas Copco Deutschland GmbH.

A suspension hydraulic temporary support equipment(Jia-sheng & Ming-zhong, 2011) has been introduced,along with roof type and structure the dynamic roadway roof support design is achieved.

Fig.5-3 Temporary support equipment is retracted

1. special suspension I-beams;2-connecting base;3-pushing cylinder;4-moving trolley;5-amplitude cylinder of supporting platform;6-non-fixed clamp;7-fixed clamp;8-supporting platform;9-leg amplitude cylinder;10-leg cylinder;11-amplitude cylinder of board to shield front wll;12-board to shield front wll;13-wall in roadway;14-hook;15-first elevating platform;16-second elevating platform;17-third elevating platform;18-roof bolt;19-roadway floor;21-rock or coal in roadway;22-roadheader

Through detection of roof type and structure,the situation that roadway support is designed by experience in coal mines can be changed, and dynamic roadway roof support design is achieved. Through matching of bolter and geological drilling rig, and roadheader, safe rapid support and excavation is achieved,as shown in Fig.5-3.

shift cylinders having the stroke of 300 mm

pipe-type guides

Four shift cylinders

Four identical inside sets

two marginal sets

Fig. 5-4 General view of six element set of the mechanized,temporary support,

according to the preliminary concept(International Mining Rorum 2011, 2010)

The manipulator or working platform moving on the rail suspended under the temporary support can be used for the support elements assembling and disassembling,as shown in 5-4.

Fig.5-5 Temporary self-advancing roof aid for the construction bolting support

The proposed temporary self-advancing roof support consists of the fixed roof shield and an expandable shield. The fixed and expandable shields are connected with its corresponding set of legs making a fixed frame and the expandable frame respectively. In the roof part of the support there should be places for the installation of the bolts and the advancing of the support should be able to avoid such installed bolts. After setting the frame against the roof the load is taken by the supporting bars which are the part of advancing system,as shown in Fig.5-5.

Fig.5-6 Bolting area layout---Belt moves, flits, relocations(CM2010)

Fig.5-7 Roof mesh carrier traverses machine

As shown in Fig.5-6,5-7,the part system of automation support mechanism consist of bolts transmission and mesh sticking the roof.

6.the technology of coal clearance

Refer to the coal clearance we should consider the efficiency to “ avoid large horse drawn trolley”,besides intelligent transportation line is the priority task that we should build them up to enhance the rate of output safety and the coincident response immediately.

The paper(22) describes the factors,affecting the rate of drivage operations,and offers the self-propelled bin-loader as part of the drivage plant for reduction of the sinking equipment downtime and support operations duration,as shown in Fig.6-1.

laser

self-propelled bin-loader

extension rod

airborne roofbolter

Fig.6-1 bump-bin and airborne roofbolter

7.the safe speedy transportation

Logistics play an important role in the integrated road- way drivage system. A typi- cal example of this development is greater component loads and increasing material transport. Monorail material transport systems have to meet these new challenges. The I140V+N (Fig.7-1) rail system is suitable for monorail conveyor operation with heavy trolley loads and frequent utilization in very inclined routes or with fast transport(Rautenstrauch & Kulassek, 2014).

Fig.7-1 monorail systems

Besides,truck can also be used in the better geological conditions.On the contrary,we may adopted the continuous coal haulage(Joy 4FCT) (Fig.7-2) when encounter a turn or more of them(Zhang et al., n.d.).

Fig.7-2 Continuous coal haulage

8.the Efficiency of machine output

We should avoid overload and power-surplus when it comes to the efficiency of machine output.A roadheader performance prediction model was developed using ANN approach in which the ICR can be predicted more precisely. with MLP and KSOFM for supervised and unsupervised ones, respectively.The results showed that the neural network had a strong capability to predict and evaluate the performance of medium-duty roadheaders in coal measure rocks(Copur, Ozdemir, & Rostami, 1998).The results of full-scale rock-cutting tests conducted with aconical cutter(Copur, Tuncdemir, Bilgin, & Dincer, 2001) in the laboratory combined with geological and geotechnical information collected during mine visits have indicated that many mines in Turkey could be operated with partial-face excavation machines, such as roadheaders and impact hammers/breakers, and that acceptable production rates could be achieved.

A good relationship was found to exist between these two parameters and the machine power (P), weight (W) and the rock compressive strength (UCS). A measure of rock mass characteristics of the RQD value lead to the formulation of an accurate roadheader performance prediction model which can be used in different rock types where the roadheaders are economically applicable(Copur et al., 1998). Research (23)suggest that hard rock with the low speed and high torque while soft rock with the fast and efficient operation can reduce the wear and tear.The motor and transmission system vibration of the roadheader, does not need a two-speed motor to regulate speed in a traditional way,which is equipped with the power reflux hydraulic transmission system is markedly attenuated relative to the existing roadheader(Wang, Sun, & Qin, 2016).

9.the self-diagnosis of automation system(24)

10.the dust removing equipment- air curtain/ long pressure short evacuation/ air curtain/ foam water injection/ wet air blower

11.the pre-mining systems

Develop pre-mining systems, including gas drainage, seam dewatering, and the detection and pre-treatment of faults and other geological anomalies, to enable a safe, compliant and productive mining environment to be maintained.Such as shown in Fig.11-1,wheeling road concrete and dig ditch can be completed consequently when roadheader advanced(CM2010).

50MPA Concrete Laid up to the back of the Continuous Miner

Dig ditch

Wheeling Road Concrete

Fig.11-1 Auxiliary process

12.the others

The bringing together of knowledge from previous experiences on underground metalliferous and civil tunneling works (boring machine(Shen et al., 2012)), has enabled the development and implementation of alternative excavation systems to construct drifts to meet differing project objectives(Donnelly, 2014).Rock fracturing by plasma blasting technology is a new non-traditional rock breaking methods,in which the research was undertaken-thermal stress induced by dielectric or induction heating, plasma-hydraulic fracturing where a shockwave or pressure wave is derived from an underwater discharge or plasma, and open pulsed electrical discharge techniques. Other comminution and spalling mechanisms were also considered,including various ablation and microwave fragmentation methods(as shown in Fig.21-1, electrofracture equipment).

Fig.12-1 System overview of the high energy,EHT’phase III’Marx generator

CONCLUSION

The major improvements achieved in the last 50 years consist of steadily increased machine weight,size and cutterhead power,improved design of boom,muck pick up and loading system,more efficient cutterhead design,metallurgical developments in cutting bits,advances in hydraulic and electrical systems,and more widespread use of automation and remote control features. In comparison with other studies in this field(25),we characterized by partially researching,inferior field practice and lacking suitable reference theories,barely researching tools as well.Of course, geological conditions play a signification role as to whether we can deliver the rapid excavation line to the particular ones(26).For instance,mining conditions in the Xinwen Coal Group now and in the future will not normally favour bolter miners or continuous miners as bolting needs to be undertaken close to the face, with little delay. We can see advanced drivage and intelligent roadheader will progressively reduce the physical demands on personnel engaged in the development process and reduce their exposure to workplace hazards in the future coal mining industry.

Acknowledgements On the completion of my thesis, I am greatly indebted to my supervisor Prof. Ju who gave me valuable instructions. I would like to express my gratitude to Prof. Liu who has improved me in language. I also would like to thank my partner Slin and Pong for their friendship and suggestions. I appreciate the authors of the literatures who have greatly contributed to this paper.

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