LONGWALL FACE SUPPORT IN AN UNDERGROUND MINE
20170019641 ยท 2017-01-19
Inventors
Cpc classification
H04N7/181
ELECTRICITY
E21D23/04
FIXED CONSTRUCTIONS
E21D15/00
FIXED CONSTRUCTIONS
E21C35/24
FIXED CONSTRUCTIONS
International classification
H04N7/18
ELECTRICITY
E21D15/00
FIXED CONSTRUCTIONS
E21D23/00
FIXED CONSTRUCTIONS
E21D23/14
FIXED CONSTRUCTIONS
Abstract
The invention relates to the longwall face support of an underground mine having supports (plates 1-18), which longwall face support comprises camera housings (35) each having two cameras (36), which record a monitoring area of the face having a plurality of plates in the longitudinal direction of the gallery and the most complete registration possible of the cross section of the gallery. The cameras in a monitoring area are assigned to a common power supply unit (48) for the power supply and are equipped with intrinsically safe electronics. The electronics have a radio device for high-frequency data transfer (transmission and reception) together with antenna 39 (W-LAN antenna) for the wire-free connection to the local camera network (Wireless Local Area Network). Each camera and each camera housing is assigned a camera code and an address code, which is added to the identification data. Each radio device is configured such that data marked with an extrinsic camera code and data and signals marked with an extrinsic address code is emitted to be transmitted following reception.
Claims
1.-18. (canceled)
19. A longwall face support in an underground mine with support frames (shields), comprising: shield control devices that are connected with the outstation (longwall control device) by a communications bus with data wires for data transmission and power lines for power supply and the power lines of which are connected with power supplies installed at intervals of distance from each other, and support units in the mining sector of the mining machine, in particular a coal cutting or milling machine, are arranged close together along the longwall and together with the conveyor form a passage (drive-through cross-section), into which intrinsically safe cameras with electronic light detection attached to the support frames are pointed, wherein the cameras are connected to the outstation for data transmission, wherein along the longwall at intervals of several support frames apart (monitoring area), camera groups of two cameras each with opposite optical alignment in the longitudinal direction of the passage and providing as complete as possible detection of the drive-through cross-section of the passage are attached, preferably in a camera housing for each camera group, to each one of the support frames in the monitoring area, wherein the two cameras (36) of each camera group are equipped with intrinsically safe electronics (38), which contain a data processor, data memory and a radio device (39) for high-frequency data transfer (transmission and reception) plus an antenna (wireless antenna) for wireless connection to a local area network (Wireless Local Area Network), and wherein each camera and camera group is assigned an address code, which is added to the received data for the purposes of identification of the addressed camera.
20. The longwall face support according to claim 19, wherein the longwall control device (outstation) contains a radio device for high-frequency data transfer (transmission and reception) plus an antenna (wireless antenna) for wireless connection to the wireless local network of cameras (Wireless Local Area Network; camera WLAN, camera network).
21. The longwall face support according to claim 19, wherein the camera network, in areas that are prone to radio interference or that are too long or complex for WLAN connections, particularly between the longwall control device (outstation 33) and the nearest camera group or island of several adjacent groups of cameras, is established by means of fiber optic conductor or cable.
22. The longwall face support according to claim 19, wherein several groups of cameras are assigned to receive power from a common power supply unit.
23. The longwall face support according to claim 19, wherein each camera and each camera group, is assigned a camera code that is added to the transmitted data to identify each individual camera group, and preferably also for the determination of the optical orientation of the transmitted image data.
24. The longwall face support according to claim 23, wherein the electronics of each camera group are set up so that data and signals marked with a different camera code and with a different address code are broadcast for transmission immediately upon being received.
25. The longwall face support according to claim 19, wherein the longwall control device comprises a display screen for representation of the transmitted image data, and that the image data is preferably also transferred to the surface.
26. The longwall face support according to claim 19, wherein the data and signals, in particular emergency signals and emergency stop signals between the shield control devices and the longwall control device are transmitted redundantly or alternatively via the control bus and via the camera network, wherein the longwall control device (outstation) and the shield control devices preferably have interfaces for data transfer between the control bus and the camera network.
27. The longwall face support according to claim 19, wherein for controlling the mining operation of the mining machine and for controlling the support operation, in particular the support frames and channel, the mining machine has means of data acquisition for detecting the position and/or the operating state and/or the instantaneous flow rate and/or the instantaneous torque and/or the type of rockand the course of the coal seam and is wirelessly connected by a radio device for high-frequency data transfer (transmission and reception) with an antenna (WLAN antenna) to one of the groups of cameras and the camera network.
28. The longwall face support according to claim 19, wherein for controlling the mining operation of the mining machine and for controlling the support operation, in particular the support frames and channel, the electronics of the cameras are able to support automatic image evaluation, enabling automated hazard detection, in particular through the storage of known predetermined image data (target image data), the acquisition of current image data (actual image data), the comparison of stored target image data and current actual image data, the detection of differences in images, and the detection and signaling of recognized hazard or enabling situations.
29. The longwall face support according to claim 28, wherein for the storage of predetermined target image data, the target drive-through cross-section is stored in the memory of the longwall control device as a drive-through model or contour model with reference points for dimensions, and for the acquisition of current actual image data, the electronic cameras repeatedly record upon each approach of the mining machine the image of the drive-through cross-section actually present perpendicular to the direction of travel with a known predetermined degree of reduction (zoom factor), the actual position of the reference points is measured, preferably by image evaluation of the actual image data, the captured actual image is transmitted with the determined position of the reference points of the longwall control device, and for the detection of differences in images, the longwall control device performs a surface comparison by means of a suitable program and matches the drive-through model or contour model to the actual camera image captured by the camera to the predetermined reference points, which are present in both images and mark identical elements of the drive-through cross-section, preferably at one or more of the reference points and provides a signal that is processable for drive enabling to the operating control of the mining machine if the images match each other without overshoot.
30. The longwall face support according to claim 28, wherein for the storage of known predetermined image data (target image data), the dimensions of selected characteristic elements of the required drive-through cross-section, which the mining machine with its cutting drums in given positions requires for unimpeded drive-through, are acquired as selected target parameters of the drive-through model with one of the following dimensions: slope, distance or length, and are stored in the memory of the longwall control device, and for the detection of actual image data, the electronic cameras repeatedly record upon each approach of the mining machine the image of the drive-through cross-section actually present perpendicular to the direction of travel with a known predetermined degree of reduction (zoom factor), the captured image data is transmitted to the longwall control device, and for detection and signaling of recognized hazard or release situations, the longwall control device, by means of a suitable program for image evaluation, recognizes the identical characteristic elements in each of the actual images of the drive-through cross-section transferred and measures the actual values of the selected parameters in terms of slope, distance or length to determine the actual image data, the longwall control device provides a signal that is processable for drive enabling to the operating control of the mining machine dependent on whether and how the actual image data of the respective parameters matches with or deviates from the target image data of the respective parameters of the drive-through model.
31. The longwall face support according to claim 29, wherein the dimensions of the structural components of the longwall support (support frame, channel, cable attachment plate, conveyor) and the mining machine, in so far as they serve to determine the drive-through cross-section, with one of the following dimensions: slope, distance, or length, as well the reference points for dimensions, are clearly determined, stored in the memory of the longwall control device and are used with the other suitable parameters for producing the drive-through/contour model of the drive-through section.
32. The longwall face support according to claim 28, wherein at least three of the following conditional values: Pressure in the pit props for determining whether the support is set and firmly clamped by means of pressure sensors in the pit props; Pressure and/or stroke of the advance cylinder for determining the distance between the conveyor and the support by means of pressure sensors and/or stroke sensors at the advancing cylinders; Position of the pusher bar relative to the roof by means of a pressure sensor or distance measuring device in the pusher bar; Position/Tilt position of the flipper bar in particular by means of an inclinometer; Slope of the roof in the direction of the coal face in particular by means of an inclinometer; Slope of the conveyor, in particular perpendicular to the direction of conveying (direction x) in particular by means of inclinometers in the channels or the conveyor pan; Slope of the base plate/skid in the direction of the coal face in particular by means; of an inclinometer on this component are determined by appropriate measuring devices installed in appropriate measurement positions upon determination of the target cross-section of the required drive-through cross-section and stored in the memory as target values, as well as being determined again repeatedly upon the determination of the actual cross-section and are compared as actual values of the conditional values with the stored target value, and wherein the control device only provides a signal that is processable for drive enabling to the operating control of the mining machine if the difference resulting from the target/actual comparison remains within the predetermined limits.
33. The longwall face support according to claim 19, wherein the characteristic elements constituting the drive-through cross-section in the passage, which serve as image points and/or reference points, are made distinguishable by attaching markings, luminous plates, luminous strips, color markings or the like.
34. The longwall face support according to claim 19, wherein for the purposes of detection of persons, reflective strips are affixed to prominent components of the shield structure and that any disturbance of the image of the reflective strips is signaled as a hazard in the image processing and evaluation of the recorded images of the drive-through cross section.
35. The longwall face support according to claim 19, wherein for the purposes of detection of persons, cameras of a second camera system are installed between the pit props at regular intervals, preferably at a distance of two shields away, and preferably with their own private network and private addressing range.
36. The longwall face support according to claim 34, wherein for the purposes of illumination of the drive-through cross-sections infrared light is also used and it is detected through image processing whether any disturbance of the image of the reflective strips is caused by persons.
37. The longwall face support according to claim 30, wherein the dimensions of the structural components of the longwall support (support frame, channel, cable attachment plate, conveyor) and the mining machine, in so far as they serve to determine the drive-through cross-section, with one of the following dimensions: slope, distance, or length, as well the reference points for dimensions, are clearly determined, stored in the memory of the longwall control device and are used with the other suitable parameters for producing the drive-through/contour model of the drive-through section.
Description
[0029] An exemplary embodiment will be described below with reference to the drawing. Shown are in:
[0030]
[0031]
[0032]
[0033]
[0034]
[0035] In
[0036] Each of the longwall support units serves the purpose of supporting the longwall. To this end, further cylinder-piston units, such as 30, are used, which brace a base plate 26 in relation to a roof plate 27. At its front end facing the coal seam, the roof plate is fitted with a so-called coal face catcher 28.
[0037] This catcher is a flap that can be lowered in front of the mined coal face. It is necessary to raise the coal face catcher 28 ahead of the approaching coal cutting machine 21. Likewise to this end, a further cylinder-piston unit (not shown) is used.
[0038] The coal face catcher 28 may be pivotally mounted on the front of a pusher bar 52. The pusher bar can be retracted and extended by means of a cylinder-piston unit (not shown here) along the plane of the roof plate to extend protection of the roof plate in the direction of the coal face. It is retracted as the mining machine approaches. These functional elements of the individual support frame are shown here only as an example. Other functional elements are present; these include additional power units, in particular hydraulic cylinder-piston units on the one hand, and also sensors (not shown here) to control automatic operation on the other hand. Said cylinder-piston units are operated via valves and electro-hydraulically activated solenoid pilot valves.
[0039] In
[0040] As a function of the movements of the coal cutting machine and its position at any given time, movements are controlled in part automatically based on a stored program, and in part manually, locally or by remote control.
[0041] Longwall support and mining is controlled from the aboveground main control center 50 and/or the underground auxiliary control center 33, also referred to as a control station or longwall control device. The control station is not located in the longwall but in one of the side galleries, from which the longwall is mined out. In the main control center 50 and/or the auxiliary control center 33, the program for automatic operation of the support control and for automatic entry of support commands (extract, advance, setting of support shields) depending on the position of the mining machine. In addition, the retrieval of the measurement values (sensor signals) from the individual sensors by the main control center 50 and/or the auxiliary control center 33 may be programmed. It is also possible to issue commands and retrieve the sensor signals manually from main control center 50 and/or the auxiliary control center 33.
[0042] Each longwall support frame is associated with a shield control device 34. Each shield control device 34 is connected to the functional elements of its support shield, and in particular to the sensors and the actuating magnets of the pilot valves and/or main valves of the power transmitters. Details can be found in the cited prior art.
[0043] The shield control devices 34 receive their command signals from the longwall control stationin this exemplary embodiment from the underground auxiliary control center 33 in one of the galleries.
[0044] The control center is equipped with a screen 31 on which the mining and support process can be visualized for the operator, who can intervene via an input device 32 if necessary and in particular in case of emergency issue emergency signals and/or emergency stop signals.
[0045] Signals and commands are transmitted via the multi-core cable 58 (communications bus, control bus). It connects all shield control devices 34 to each other and to the control station 33. The cable is also used to power the support frames, for example, the control solenoids of the hydraulic valves.
[0046] Due to the high number of shield control devices 34, the control bus is subdivided with converters 59 at intervals of every few support frames and the power cables are connected here to the power supplies 60. The power supplies are connected to the central power supply via a line 61.
[0047] Via each of the shield control devices, the support commands, status data and other data entered at or sent from the control station are received by all the other shield control devices and passed on to all other shield control devices, as well as to the control station.
[0048] By means of a predetermined code (shield code word), only one of the shield control devices of shields 1-18 or a group of shield control devices can, however, be activated to perform the requested function, such as a measurement value request or support function e.g. for the purposes of extraction, advancing, or setting. The activated shield control device then converts the received function command, for example a measurement value request or support command, into a command to be sent to the functional elements, sensors, control valves and main valves associated with the support shield concerned.
[0049] The activation of the shield control device of a particular support shield and the automatic triggering of functions and functional processes is described for example in DE 195 46 427.3 A1.
[0050] It is clear that processes of movement in a longwall are very complex and because of the specific nature of the local situation cannot be supervised and predicted by a single person.
[0051] Therefore, the operation of the mining machine is, according to the invention, supported by the use of cameraswith the goal of achieving full automation, which, with the deployment of a low amount of measurement resources, makes it possible to replace or support the human monitoring of mining operations, and in particular allows avoidance of collisions between mining machines and support structures.
[0052] For this purpose, the main control center 50 and/or the longwall control device/auxiliary control center 33 has a storage capacity, in which a model 51 of the required drive-through cross-section is saved for all longwall cross-sections within a distance of one support frame. Such a model 51 is shown in
[0053] Since the support structure is made up of identical support frames, the drive-through model is generated for the longwall once manually or through test runs with corresponding adjustment made to the mining machine. It is defined as the contour of the surface which is marked here with a dot-dashed outline, and is stored in this form in the memory of the longwall control device. It may, however, also be determined by characteristic structural components of the available drive-through cross-section and their dimensions. Such structural components, their dimensions, the measurement points and reference points for their dimensions are indicated in
[0061] These parameters form a polygon that, if appropriately reduced in size, taking constant or specific given characteristics of the longwall cross-sections into account, can be used as a drive-through model and be stored with these parameters in the memory of the longwall control device.
[0062] For each approach of the mining machine, the actual available drive-through cross-section of each of the support frames, channels, etc. is now determined. The cameras according the invention are used to determine such data.
[0063] The camera housings 35 with two cameras 36 each are mounted at a distance of several shields apart with opposite detection areas 37 in the longitudinal direction of the longwall on each shield concerned. The camera housings are spaced out at a distance of several shields apart, but are arranged close enough to each other that the fields of view of the longitudinally adjacent cameras overlap in the longitudinal direction in such a way that reliable image evaluation is always possible. The conditions of the mining operatione.g. height of the longwall, visibility conditions, dust and pollution, as well as the manner in which the camera system is integrated into the operationfor example only to facilitate manual operation, redundancy for manual operation or full automation and in particular the resulting safety requirements are factors in determining the distance between the camera housings. A distance of every 3 to 8 shields apart may be considered.
[0064] It should be noted that there is a tendency to attempt to limit the number of cameras, as with a greater number of cameras the probability of failure increases, which then leads to the shutting down of the whole mining operation in the longwall.
[0065] The cameras detect, within their detection area 37 transverse to the longwall, the free cross-section of longwall below the roof 27 including the cable attachment plate, the channel and the working area of the cutting machine. Along the length of the longwall, the detection area 37 covers several shields (monitoring area).
[0066] Adjacent monitoring area/detection areas 37 can also overlap as a precautionary safety measure.
[0067] In this defined detection area, not only is the presence of a person detected but any optically visible irregularity in mining operationse.g. broken down coal seam wall in the area of movement of the coal cutting machineand in support operationse.g. an unretracted coal face catcher 28, unretracted shieldsis also detected and transmitted to the control station in the form of an image file or as a warning signal or emergency signal after the image data has been evaluated.
[0068] Two cameras are accommodated in each camera housing 36. There is an angle of about 120 between their optical central axes. This angle depends on the field of view of the cameras. This field of view is indicated in
[0069] Besides the two cameras 36, each camera housing 35 is equipped with the camera electronics 38 with processing capacity, memory and a transmitter/receiver for high-frequency radio signals, as well as a radio antenna 39. Some of the adjacent camera housings may also be connected to each other via data cable 40. These camera housings form a camera island from which data is transferred to the next camera housing and/or to the next camera island via radio link. In this way, some of the camera housings can be provided without radio equipment and antennas. However, it is preferable that all of the camera housings be equipped with radio for reasons that will be discussed later.
[0070] To communicate with the mining and support operation, the camera housings are thus integrated by radio and antenna 41 and data cable 40 into a local area network (Wireless Local Area Network).
[0071] The camera electronics 38 are configured so that incoming data via radio or data cable, which is not intended for one of the cameras 36 of the respective camera housing, is sent on immediately.
[0072] The last camera housing in the longwall is preferably connected to the control station 33 via fiber optic cable 42 (not shown) or electronic cable for data transmission.
[0073] Evaluation may in the simplest case be carried out by laying the actual image file over the drive-through model saved as an area at reference points which are present in both imagese.g. at the top of the cable attachment plate.
[0074] A warning or emergency signal or release signal is then generated depending on whether the stored drive-through model in the actual image file fits with the reference points without any overshoot.
[0075] Otherwise, the evaluation can be carried out by determining whether the characteristic elements described above, the dimensions of which are based on the drive-through model, fit with the available drive-through model. For this purpose, the dimensions of these structural components in the recorded actual image file are measured, taking account of the measurement points and reference points for measurement, and it is determined whether the stored drive-through model fits into the polygon formed by these actual parameters, or if the parameters stored in the memory of the longwall control device match the parameters from the actual image file or deviate from them outside the permitted limits.
[0076] It is known from experience that proper and trouble-free mining and support operations also depend on factorsespecially non-geometric factorsthat cannot be captured in a geometric model. In this respect, reference is made to claim 2. It is therefore envisaged that a sufficient number of these factors can be monitored simultaneously with the model comparison.
[0077] The processing capacity is used to detect any deviations determined based on the comparison and evaluates them according to prescribed rules and algorithms and/or reports them to the control station 33, where they are displayed on the screen 31 and are evaluated by the operator and used to control the mining and support operation. It is also possible to use the evaluation in the camera housings directly to generate a signal or an emergency signal if they are connected, as interference-free radio transmission is not always guaranteed in the area of the gallery.
[0078] Otherwise, radio transmission is also possible. The camera data is thus received at the control station 33 and displayed on the screen 31. The operator can respond as appropriate via the input device 32, if the image data transferred does not appear to be as required or is not useful.
[0079] Practical is above all the operation of those cameras and camera housings that are located in the area just before, at and just after the current position of the mining machine. It is preferable that the operation of the cameras outside of this zone be turned off and similarly that the lighting only be switched on when the mining machine is approaching.
[0080] Other than that it will be evident that a camera monitoring system with image data evaluation, as envisaged according to the invention, is only possible if the longwall area to be monitored is illuminated appropriately. Though it cannot be shown clearly here, the illumination can be improved on the one hand by marking strips, luminous plates and the like at points to be highlighted, and on the other hand also by the blending in of infrared light.
[0081] Not only is the presence of a person detected in the defined detection areas but also any optically visible irregularity in mining operationse.g. broken down coal seam wall in the area of movement of the coal cutting machineand in support operationse.g. an unretracted coal face catcher 28, unretracted shieldsand above all the drive-through cross-section in front of every support frame is detected.
[0082] This drive-through cross-section is passed on to the control station 33 as an actual image file, where it is stored and evaluated according to predefined rules and algorithms. It is envisaged that the cameras 36 perform a complete image data acquisition. In this case, the image data can be stored in the memories of the camera housings. In addition, the processing capacity is designed in such a way that the currently recorded image data can also be compared with older, for example, the most recent image data.
[0083] There are two options for evaluation of the actual image files recorded by the cameras
[0084] to recognize or anticipate deviations in, or a hazard or threat of disruption to mining operations or support operations.
[0085] According to the invention, the camera network is provided as a redundant and alternative network for data transmission to the communications bus 58. To this end, the converters 59 described above are equipped with a radio device and antenna 53. This makes it possible to transmit data in parallel or as an alternative to data transmission via the communications bus 58 over the camera network orespecially when there are disruptions in sections of the communications bus 58over the parallel section of the camera-network by means of antennas 39 and/or data cable 40. This is particularly advantageous because data transmission via the communications bus 58 is relatively sluggish due to the necessary conversions, while the relayed data transmission over the camera network is much faster and therefore particularly suitable for emergency signals and emergency stop signals. However, it is also possible, in the case of failure of communications bus 58 to transmiteither wholly or even just partiallythe necessary control data for mining support and for the mining machine via the camera network.
[0086] It is already known (see above) how to acquire rock data or other data from the mining machine by special sensors on the mining machine and how to store such data using appropriate electronics for operating data acquisition 41 fitted to the mining machine. This data is then transmitted by radio to some of the radio receivers set out at fixed points along the longwall and to the control station; the best or the most digitally complete signal respectively is used for mining operations.
[0087]
[0088] It is to be noted that data transmission from the control station via the communications bus to the individual support frames with their shield control devices is designed in such a way by means of encryption and coding of data that the addressees and senders of signals and commands can be identified and the data and signals are always assigned to the correct transmitter or receiver.
[0089] The additional camera network provided according to the invention not only opens up the possibility of a second data network but also offers multiple data paths between the camera network and the regular data network. In addition, the cameras and camera housings are included in the loop of addressees and senders of data and commands. According to the invention, it is also envisaged that the data traveling over the camera network is encrypted using an appropriate coding that allows for identification and addressing. Furthermore, data which has already been sent once is identified on the camera network, so that it is not sent from the same transmitter a second time. This can, for example, be done by adding to the data, for example image data, not just a signal identifying the location and direction of the image recording but also a time signal.
[0090] In a further development of the invention, another set of cameras (not shown) is now installed along the longwall. These cameras are arranged with greater density and greater redundancy and their coverage overlaps because they are to be used for person detection. Their detection range can, however, also be limited within the cross-section of the longwall to the area in which persons are expected to be present. These person detection cameras are assigned a second independent camera network. This creates a further alternative and/or redundancy of data transmission, since it is also envisaged that this camera network can communicate by wire or radio devices with the communications bus 58 or with the first camera network.
NUMERALS
[0091] 1-18. Support units 1 to 18, support shield, shield [0092] 20. Coal seam 20 [0093] 21. Mining extraction machine Coal cutting machine Milling machine Mining machine 21 [0094] 22. Working direction 22 [0095] 23 Cutting device, Cutting drum [0096] 24 Cutting device, Cutting drum [0097] 25 Conveyor, Channel, Unit, Course 25 [0098] 26 Base plate, Skid 26 [0099] 27 Roof plate, Roof 27 [0100] 28 Coal face catcher 28 [0101] 29. Cylinder-piston unit, Advance piston, Power transmitter 29 [0102] 30. Cylinder-piston unit, Power transmitter [0103] 31. Screen 31, [0104] 32. Input device, Keyboard 32 [0105] 33. Underground control center, Central control station, Longwall control device, Central mining and support control, Longwall control device 33 Devices for longwall/central control [0106] 34. Device controller 34, Shield control device, Support control [0107] 35. Camera housing 35 [0108] 36 Camera 36 [0109] 37. Detection area [0110] 38. Camera electronics [0111] 39 Radio antenna, Camera antenna, Wireless antenna, Transponder 39 [0112] 40 Data cable, Camera data cable [0113] 41 Antenna, Mining antenna, Operating data acquisition, Device [0114] 42 Fiber optic cable [0115] 47 Radio device with antenna [0116] 48 Power supply Camera power supply [0117] 49 Converter [0118] 50. Main control center [0119] 51 Drive-through model, Contour model, Area 51 [0120] 52 Pusher bar [0121] 53 Transmitter, Antenna [0122] 58 Cable, Communications bus, Signal line 58 [0123] 59 Converter [0124] 60 Power supply 60 [0125] 61 Line 61 [0126] 63 Slope gauge, Inclinometer
[0127] Within the framework of this application, the terms out station, control station, control center, longwall control system, longwall control device are used synonymously to designate the control device for controlling mining and support operations located in one of the galleries or above ground. The terms shield control or shield control devices are subsumed to designate the control devices attached to each support frame, which are networked together via a bus system, in this application referred to as a control bus.