阅读说明：本技术 采掘机的稳定系统 (Stabilization system for mining machine ) 是由 科林·安东尼·瓦德 雅各布斯·伊格内修斯·约恩克 于 2012-08-03 设计创作，主要内容包括：采掘机的稳定系统,该采掘机包括：框架；可移动地联接到框架和可绕基本垂直于第一矿井表面的轴线枢转的刀头：以及用于使框架相对于第一矿井表面稳定的第一致动器。第一致动器联接到框架且包括可沿第一方向伸展以接合第一矿井表面的第一端部。第一致动器的伸展根据在第一致动器和第一矿井表面之间的力的至少一个指示的测量而得以自动控制。(A stabilization system for a mining machine, the mining machine comprising: a frame; a cutter head movably coupled to the frame and pivotable about an axis substantially perpendicular to the first mine surface: and a first actuator for stabilizing the frame relative to the first mine surface. A first actuator is coupled to the frame and includes a first end extendable in a first direction to engage a first mine surface. Extension of the first actuator is automatically controlled based on measurement of at least one indication of force between the first actuator and the first mine surface.)

1. A mining machine, the mining machine comprising:

a frame;

a cutter head movably coupled to the frame;

a first actuator for stabilizing the frame relative to a mine surface, the first actuator coupled to the frame and including a first end expandable in a first direction to engage the mine surface; and

a control system in communication with the first actuator and configured to operate the first actuator, the control system including a timer for detecting a time required for the first end to extend to a position such that at least one indication of force between the first actuator and the mine surface reaches a predetermined value, the control system controlling the extension of the first end in accordance with the detected time.

2. The mining machine of claim 1, further comprising a second actuator for stabilizing the frame relative to the mine surface, the second actuator coupled to the frame and including a first end extendable in a second direction to engage the mine surface, the control system in communication with the second actuator and configured to operate the second actuator, the control system detecting a time required for the first end of the second actuator to extend to a position such that at least one indication of force between the second actuator and the mine surface reaches a predetermined value, the control system controlling the extension of the first end of the second actuator as a function of the detected time.

3. The mining machine of claim 1, further comprising a second actuator for stabilizing the frame relative to a second mine surface, the second actuator coupled to the frame and including a first end extendable in a second direction to engage the second mine surface, the control system in communication with the second actuator and configured to operate the second actuator, the control system detecting a time required for the first end of the second actuator to extend to a position such that at least one indication of a force between the second actuator and the second mine surface reaches a predetermined value, the control system controlling the extension of the first end of the second actuator as a function of the detected time.

4. The mining machine of claim 1, further comprising a headboard pivotably coupled to the first end of the first actuator and configured to engage the mine surface.

5. The mining machine of claim 4, wherein the headboard is pivotably coupled to the first end of the first actuator by a ball and socket joint.

6. The mining machine of claim 4, wherein the headboard includes a substantially triangular profile.

7. The mining machine of claim 1, further comprising at least one spacer positioned between the first end of the first actuator and the first mine surface.

8. The mining machine of claim 1, wherein the first actuator is a hydraulic cylinder and the at least one indication of force between the first actuator and the mine surface is a hydraulic pressure within the hydraulic cylinder.

9. The mining machine of claim 1, wherein the first actuator is a hydraulic cylinder, and further comprising a directional control valve for controlling fluid flow into and out of the first actuator to extend and retract the first actuator.

10. The mining machine of claim 1, wherein the cutter head is pivotable about an axis generally perpendicular to the mine surface and includes at least one oscillating disc cutter.

11. The mining machine of claim 1, further comprising a sensor in communication with the controller, the sensor detecting the at least one indication of force between the first actuator and the mine surface.

12. The mining machine of claim 1, the sensor detecting a pressure sensor of the pressure in the first actuator.

13. A mining machine comprising:

a frame;

a cutter head supported for movement on the frame;

an actuator for stabilizing the frame relative to a mine surface, the actuator coupled to the frame and including an end extendable in a first direction to engage the mine surface; and

a control system configured to operate the actuator, the control system configured to retract the actuator for a predetermined amount of time from a position where at least one of the forces between the actuator and the mine surface is indicative of a specified range being met, and extend the actuator for the predetermined amount of time plus an additional amount of time.

14. The mining machine of claim 13, wherein the actuator is a first actuator and the mine surface is a first mine surface,

the mining machine further comprising a second actuator for stabilizing the frame relative to a second mine surface, the second actuator coupled to the frame and including an end extendable in a second direction to engage the second mine surface,

wherein the control system is configured to operate the second actuator, the control system configured to retract the second actuator for a predetermined amount of time from a position where at least one of the forces between the second actuator and the second mine surface is indicative of a specified range being met, and extend the second actuator for the predetermined amount of time plus an additional amount of time.

15. The mining machine of claim 13, further comprising a headboard coupled to the end of the actuator and configured to engage the mine surface.

16. The mining machine of claim 15, wherein the headboard is pivotably coupled to the end of the actuator by a ball and socket joint.

17. The mining machine of claim 15, wherein the headboard includes a substantially triangular profile.

18. The mining machine of claim 13, further comprising a spacer positioned between the end of the actuator and the mine surface.

19. The mining machine of claim 13, wherein the actuator includes a hydraulic cylinder and the at least one indicator of force between the actuator and the mine surface is hydraulic pressure within the hydraulic cylinder.

20. The mining machine of claim 19, further comprising a directional control valve for controlling fluid flow into and out of the actuator to extend and retract the actuator.

21. The mining machine of claim 13, wherein the cutter head includes at least one oscillating cutter disc supported for centrifugal movement.

22. The mining machine of claim 13, further comprising at least one of: a pressure sensor that detects the at least one indication of force between the first actuator and the mine surface; and a displacement sensor that detects a position of the first actuator.

Technical Field

The invention also relates to a mining apparatus and in particular to a continuous mining machine.

Background

Traditionally, excavation of hard rock in the cutting and construction industry has taken one of two forms of blasting excavation or hemming cutter excavation. Blasting mining entails drilling relatively small diameter sample holes in the rock being excavated and filling the holes with explosives. The explosive charge is then detonated in a sequence designed to subsequently remove the required volume of rock fragments by suitable loading and transport equipment. However, the relatively unpredictable size distribution of the rock products formed complicates downstream processing.

Mechanical crushing of rock eliminates the use of explosives; however, the hemming cutter needs to apply a very large force to crush and break the rock in the excavation situation. Conventional underground mining operations can cause the roof (also referred to as the roof) and walls of the mine to become unstable. To prevent the walls from collapsing as the miner digs deeper into the mineral seam, hydraulic cylinders are used to support the mine walls. To support the upper disc, the hydraulic cylinder must typically bear against the upper disc with a force of over 40 tons. This force causes the hydraulic support to dig into the upper disc, which weakens the upper disc and increases the risk of rock fall.

Disclosure of Invention

One embodiment of the present invention provides a mining machine including a frame; a cutter head movably coupled to the frame and pivotable about an axis substantially perpendicular to the first mine surface; and a first actuator for stabilizing the frame relative to the first mine surface. A first actuator is coupled to the frame and includes a first end extendable in a first direction to engage a first mine surface. Extension of the first actuator is automatically controlled based on measurement of at least one indication of force between the first actuator and the first mine surface.

Another embodiment of the present invention provides a method of stabilizing a mining machine relative to a mine surface. The method includes extending at least one actuator toward the mine surface until at least one indication of a force between the actuator and the mine surface reaches a predetermined value, retracting the at least one actuator for a predetermined amount of time, and extending the at least one actuator for the predetermined amount of time plus an additional amount of time.

Yet another embodiment of the present invention provides a method of stabilizing a mining machine relative to a first mine surface and a second mine surface. The method includes extending a first actuator toward a first mine surface until at least one indication of a force between the first actuator and the first mine surface reaches a predetermined value, retracting the first actuator a first predetermined distance, extending the first actuator a first predetermined distance plus an offset distance, extending a second actuator toward a second mine surface until at least one indication of a force between the second actuator and the second mine surface reaches a predetermined value, retracting the second actuator a second predetermined distance, extending the second actuator a second predetermined distance plus an offset distance.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

Drawings

Figure 1 is a perspective view of a mining machine.

Figure 2 is a side view of the mining machine of figure 1.

Fig. 3 is a perspective view of the cutting mechanism.

Fig. 4 is an exploded perspective view of the cutting mechanism of fig. 3.

Fig. 5 is a cross-sectional view of a cutter head of the cutting mechanism of fig. 3.

Fig. 6 is a perspective view of the stabilization device in a retracted state.

Fig. 7 is a perspective view of the stabilization device of fig. 6 in an extended state.

FIG. 8 is a cross-sectional view of the stabilization device of FIG. 6 taken along line 8-8.

Fig. 9 is a side view of a headboard.

Fig. 10 is a perspective view of the headboard.

FIG. 11 is a cross-sectional view of the headboard of FIG. 10 taken along line 11-11.

Fig. 12 is a perspective view of a spacer.

FIG. 13 is a side view of the headboard and spacer in a stacked configuration.

Figure 14 is a partial side view of the mining machine of figure 1 with leveling actuators in an extended state.

Fig. 15 is a partial side view of the mining machine of fig. 1 with the leveling actuators and support actuators in an extended state.

Fig. 16 is a partial side view of the mining machine of fig. 1 with the leveling and support actuators in an extended state and further including a spacer positioned proximate to a headboard coupled to each actuator.

FIG. 17 is a schematic diagram of a hydraulic control system for the stabilization device.

FIG. 18 is a schematic diagram of a leveling selection sequence.

FIG. 19 is a schematic diagram of a leveling control sequence for automatic extension and retraction of the stabilization device.

Fig. 20 is a schematic diagram of a leveling control sequence for manual leveling of a stabilization device.

FIG. 21 is a schematic diagram of a stabilization control sequence.

Detailed Description

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in other ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms "mounted," "connected," and "coupled" are used broadly and encompass both direct and indirect securement, connection, and coupling. Further, "connected" and "coupled," whether direct or indirect, are not limited to physical or mechanical connections or couplings and may include electrical or hydraulic connections or couplings. Moreover, electronic communication and notification may be implemented using any known means, including direct connection, wireless connection, and the like.

Fig. 1 and 2 illustrate a continuous mining machine 10, the continuous mining machine 10 including a frame 14, a stabilization system 18, a cutting mechanism 22 coupled to the frame 14, and a pair of tracks 24 coupled to the frame 14, the tracks 24 for moving the machine 10. Before describing the stabilization system 18, the mining machine 10 and the cutting mechanism 22 will be described in detail.

As shown in fig. 3 and 4, the cutting mechanism 22 includes the cutterhead 26, an arm 30 defining a longitudinal axis 34, a bracket 42 for attaching the cutterhead 26 to the arm 30, and a pivot assembly 50, the pivot assembly 50 being coupled to the mining machine 10 and allowing the arm 30 to pivot about an axis 52 (fig. 1) that is substantially perpendicular to the ground or surface supporting the machine 10. In other words, the arm 30 pivots in a substantially horizontal direction. The impeller includes a flange 54 and three openings 58 (fig. 4), each of which releasably receives a disc cutter assembly 66. The disc cutter assemblies 66 are spaced apart from each other and oriented along separate axes. Each disc cutter assembly 66 defines a longitudinal axis of rotation 70, and the disc cutter assemblies 66 are spaced apart from one another and mounted at an angle such that the axes of rotation 70 are non-parallel and do not intersect. For example, in the embodiment as shown in FIG. 3, the axis 70a of the intermediate disc cutter assembly 66a is substantially coaxial with the longitudinal axis 34 of the arm 30. The axis 70b of the lower disc cutter assembly 66b is at an angle to the axis 70a of the intermediate disc cutter assembly 66 a. The axis 70c of the upper disc cutter assembly 66c is at an angle to the axis 70b of the lower disc cutter assembly 66b and the axis 70a of the intermediate disc cutter assembly 66 a. This arrangement of the disc cutter assembly 66 produces a uniform cut when the cutter disc 26 engages the mine wall. Additional embodiments may include fewer or more disc cutter assemblies 66 arranged in various positions.

As shown in fig. 5, the impeller 26 also includes an absorber mass 74, the absorber mass 74 being made of a heavy material such as lead, located in the interior volume of the impeller 26 surrounding the three openings 58. By sharing a common weight for the three eccentrically driven disc cutter assemblies 66, less overall weight is required and a lighter and more compact design is allowed. In one embodiment, approximately 6 tons is shared among the three disc cutter assemblies 66. The mounting arrangement is configured to react to approximately the average force applied by each disc cutter assembly 66, with the maximum cutting force being absorbed by the absorber mass 74 rather than by the arm 30 (fig. 3) or other support structure. The mass of each disc cutter assembly 66 is relatively much less than the absorption mass 74.

As shown in fig. 4, the arm 30 includes a top portion 82 and a bottom portion 86. The bracket 42 includes a flange 94. The bracket 42 is secured to the arm 30 in any suitable manner, such as by welding. The bracket 42 is attached to the impeller 26 by a U-shaped channel 98. Each channel 98 receives the impeller flange 54 and the bracket flange 94 to secure the impeller 26 to the bracket 42. An elastomeric sleeve (not shown) is placed between the impeller 26 and the bracket 42 to isolate impeller vibration from the arms 30.

The disc cutter assembly 66 is driven to move in a centrifugal manner. This is accomplished, for example, by driving the disc cutter assembly 66 using a drive shaft (not shown) having a first portion defining a first axis of rotation and a second portion defining a second axis of rotation that is radially offset from the first axis of rotation. The magnitude of the centrifugal movement is proportional to the amount of radial offset between the axes of rotation of each portion of the shaft. In one embodiment, the offset is a few millimeters, and the disc cutter assembly 66 is driven off-center with relatively small amplitude at high frequency, such as about 3000 RPM.

The centrifugal movement of the disc cutter assembly 66 produces a jackhammer-like action against the mined mineral causing the rock to stretch break, thereby dislodging the rock fragments from the rock surface. The force required to produce tensile failure in the rock is an order of magnitude less than the force required by a conventional hemming disc cutter to remove the same amount of rock. In particular, the action of the disc cutter assembly 66 against the lower surface is similar to the action of a chisel creating tensile stress in a brittle material such as rock, which action causes effective tensile failure. In another embodiment, the disc cutter 66 may also be pendulous such that the axis of rotation moves in a sinusoidal manner as the disc cutter 66 oscillates. This may be accomplished by angularly rotating the axis about which the disc cutter drive shaft rotates away from the disc cutter housing.

The mining machine 10 is operated by advancing the arm 30 a first incremental distance toward the material being mined, pivoting the arm 30 to cut the material, and then advancing the arm 30 a second incremental distance toward the material being mined. In operation, the lower disc cutter assembly 66b first contacts the mined mineral as the arm 30 pivots about the pivot assembly 50 in a first direction (clockwise as viewed from the top of the arm 30 in fig. 3). This causes the lower disc cutter assembly 66b to move material away from the mine wall. When the intermediate disc cutter assembly 66a contacts the mined mineral, the space below the intermediate disc cutter assembly 66a is opened by the lower disc cutter assembly 66b so that the material removed by the intermediate disc cutter assembly 66a is moved away from the wall of the mineral. Likewise, when the upper disc cutter assembly 66c engages the material, the space below the upper disc cutter assembly 66c is opened and the material displaced by the upper disc cutter assembly 66c falls to the ground. Since the preceding disc cutter is in the lowest position, the material removed by the preceding disc cutter is not crushed again by the following disc cutter, reducing wear on the disc cutters. In addition, the disc cutter assemblies 66 are positioned so that each disc cutter 66 cuts into the material being cut to the same depth. This prevents inhomogeneities in the mined mineral that can impede the progress of the mining machine 10.

The stabilization system 18 may be used in combination with the continuous mining machine 10 described above or may be used in combination with a mining machine as described in U.S. patent No. 7,934,776 filed on 8/31/2007, which is incorporated herein by reference in its entirety. The stabilizing system 18 provides additional support against rock fall and also ensures that the cutting mechanism 22 cuts on a level surface relative to the mine floor.

Referring again to fig. 1 and 2, the stabilization system 18 includes at least one stabilization device 534. In the illustrated embodiment, stabilization system 18 includes four stabilizers 534, one stabilizer 534 positioned at each of the four corners of machine 10. In other embodiments, machine 10 may include fewer or more than four stabilizers 534 and may be disposed at locations other than the four corners of machine 10.

Referring to fig. 6 and 7, each stabilizer 534 includes a housing 538, a leveling actuator 542, a support actuator 546 separate from the leveling actuator 542, and a headboard 550 coupled to an end of each actuator 542, 546. As shown in fig. 8, both the support actuator 546 and the leveling actuator 542 are mounted in parallel within the housing 538. The actuators 542, 546 include a displacement sensor 552 (fig. 8) that senses the position of each actuator 542, 546 within the housing 538. The leveling actuators 542 are used to level the machine 10, while the support actuators 546 are used in combination with the leveling actuators 542 to provide support and grip to the machine during mining. In the illustrated embodiment, the stabilizers 534 are strategically positioned relative to the machine to ensure maximum support and optimal leveling capability. In further embodiments (described below), each stabilization device 534 may also include one or more spacing devices 554 (fig. 12 and 13).

In the illustrated embodiment, the actuators 542, 546 are double-acting hydraulic cylinders and hydraulic pressure is selectively applied to either side of the pistons 544, 548 (FIG. 8) to extend or retract the cylinders. In other embodiments, actuators 542, 546 include additional types of hydraulic actuators, pneumatic actuators, electric actuators (e.g., switches or relays, piezoelectric actuators, or solenoids), mechanical actuators (e.g., bolt or cam actuators), or other types of mechanisms or systems for moving components of the mining machine.

As shown in fig. 9-11, the headboard 550 has a wide profile or footprint, with the headboard 550 providing a large support surface area. In the illustrated embodiment, the headboard 550 is generally triangular (with truncated corners). The headboard 550 includes a first side 558 for engaging an upper tray (mine roof) or a lower tray (mine floor), a second side 562 opposite the first side 558, a pair of handles 566 coupled to the second side 562, a socket 570 (fig. 11) on the second side 562, and a mounting surface 574 surrounding the socket 570. A handle 566 is provided to facilitate handling and transporting the headboard 550 for mounting on the stabilizer 534. In one embodiment, the headboard 550 is made of glass reinforced plastic and the first side 558 is bonded with a polyurethane friction material. The polyurethane material serves as a friction surface to prevent the headboard 550 from being damaged.

Referring to fig. 9 and 11, a headboard 550 is coupled to each actuator 542, 546 by a joint assembly 578. In the illustrated embodiment, the joint assembly 578 is a ball and socket type coupling. As shown in fig. 11, the joint assembly 578 includes a ball member 586, a flange 590 (which may be made of polyurethane), and a locating pin 594. Ball member 586 includes a first end 598 having a circular shape, a second end 606, and a groove 614, the groove 614 extending circumferentially around ball member 586 between first end 598 and second end 606. The first end 598 fits within the foot pan socket 570 to allow pivotal movement of the socket 570 about the ball member 586. The second end 606 has a cylindrical shape and includes a longitudinal bore 618 that fits over the actuators 542, 546.

The flange 590 of the joint assembly 578 is secured to the mounting surface 574 on the headboard 550 and is positioned within the channel 614 of the ball member 586. This arrangement allows the ball member 586 to pivot at an angle relative to the socket 570, but the pivoting movement of the ball member 586 is limited by the flange 590. The joint assembly 578 provides the stabilizer 534 with a self-aligning feature such that when the actuators 542, 546 are extended, the headboard 550 moves relative to the ball joint 578 to lie flat against the top or ground. In addition, the headboard 550 maintains its horizontal position when the actuators 542, 546 are retracted away from the top or ground. Bore 618 of ball member 586 slides over the end of one of actuators 542, 546 and is secured by dowel pin 594. A spider 550 is fixed to each of the leveling actuators 542 and the support actuators 546 in this manner.

The headboard 550 increases the efficiency of the stabilizer 534. The headboard 550 may be made of a composite material other than steel to provide reduced weight and improved handling. The headboard 550 is subjected to greater loads and provides coverage over a larger area than previous designs. The headboard 550 is durable and elastically deformable, which helps to withstand the impact caused by an explosion. The composite material used for the headboard 550 is inert and corrosion resistant. These factors give the composite headboard 550 a longer life, reducing the overall cost of the stabilizer 534. In addition, the headboard 550 applies a stabilizing force to the lower tray and the top. The headboard 550 can accommodate uneven mine roof and floor conditions through the adaptable joint assembly 578.

As shown in fig. 12, each spacer 554 includes a first side 622 and a web 626 opposite the first side 622, and a locating hole 630 positioned within the web 626. The first side 622 is adapted to engage a mine roof or the ground. The web 626 includes a plurality of plates 634 that support the necessary loads. As shown in fig. 13, the spacer 554 may be positioned between the headboard 550 and the mine roof or floor. In further embodiments, the spacer 554 may be directly coupled to one of the actuators 542, 546 by a joint assembly similar to the joint assembly 578, and the headboard 550 is then positioned between the spacer 554 and the mine roof or ground.

A plurality of spacers 554 may be stacked on a first side 558 of the headboard 550 to support a mine roof or floor. The locating holes 630 of each spacer 554 are aligned and a pin (not shown) is placed within the holes 630 to ensure that the spacers 554 remain aligned with each other in the column and do not slip off. In other embodiments, the spacer 554 may not include any locating holes. In one embodiment, the spacers 554 are made of steel and coated with a material having a high coefficient of friction. The spacers 554 support large loads in compression and have a reduced mass with a consistent strength to weight ratio. The reduced mass provides easier handling and transport.

In another embodiment (not shown), the stabilizer 534 includes a lateral actuator oriented in a horizontal direction to support the mine sidewall. The stabilization device in this case may include similar features as the stabilization device 534 described above, including a headboard 550 and a joint assembly 578.

As shown in fig. 14-16, the stabilizing device 534 performs both the leveling and stabilizing functions of the continuous mining machine 10. First, when the mining machine 10 is positioned adjacent to the wall being mined, both the support actuators 546 and the leveling actuators 542 are retracted (fig. 6). To orient the machine 10 at a proper angle to complete the mining operation, the leveling actuators 542 are then extended (fig. 14). The headboard 550 of the leveling actuator 542 engages the mine floor. Next, to ensure that the continuous miner 10 is stable during cutting operations, the support actuators 546 are extended so that the headboard 550 engages the mine roof (fig. 15). Additionally, as shown in fig. 16, one or more spacers 554 may be positioned between each headboard 550 and the mine roof and mine floor.

The stabilizer 534 is controlled by a control system 638 and the corresponding control system 638 is shown in fig. 17. However, the control system 638 is described below with reference to a hydraulic system, and a similar control system may be employed using any of a number of different types of power systems.

In certain embodiments, the control system 638 indirectly measures the physical force between the actuators 542, 546 and the mine surface. In particular, the parameters of the actuators 542, 546 may provide one or more indications of the physical force between the actuators 542, 546 and the mine surface. The control system 638 can determine whether these indications equal or exceed predetermined values to indirectly determine whether the physical force between the actuators 542, 546 and the mine surface has reached a predetermined threshold. For example, if the actuators 542, 546 include hydraulic cylinders, the control system 638 may use the pressure values of the actuators 542, 546 as an indication of the physical force applied between the actuators 542, 546 and the mine surface. Specifically, the control system 638 can extend the actuators 542, 546 toward the mine surface until the actuators 542, 546 are pressurized to a predetermined pressure value. When the actuators 542, 546 include pneumatic actuators, the control system 638 may use similar pressure values as an indication of the physical force between the actuators 542, 546 and the mine surface. In other embodiments, the control system 638 can use parameters of the current supplied to the actuators 542 and 546, force values between components of the actuators 542 and 546, or physical positions of components of the actuators 542 and 546 as an indication of the physical forces of the actuators 542, 546 and the mine surface. Other components of the machine 10, such as displacement sensors or inclinometers, may also provide one or more feedback indications of the physical force between the actuators 542, 546 and the mine surface.

In the illustrated embodiment, the control system 638 includes a control manifold 642 mounted separately from the stabilizer housing 538, the displacement sensor 552 (FIG. 8), the pressure sensor 692 (shown schematically in FIG. 17), the inclinometer (not shown), and a programmable logic controller ("PLC"; not shown). Displacement sensors 552 and pressure sensors 692 are mounted on the actuators 542, 546 and measure the position and pressure of the actuators, respectively, to provide feedback to the control system 638 regarding the force between the actuators 542, 546 and the mine surface. The inclinometer measures the inclination of machine 10 in the longitudinal and transverse directions. In other embodiments, other sensors may be used to measure an indication of the physical force between the actuators 542, 546 and the mine surface.

As shown in fig. 17, the control manifold 642 includes a leveling system 650 and a support system 654. The leveling system 650 includes a high response servo solenoid or proportional valve 662 having on-board control electronics and a fail safe position, a pressure reducing valve 666, a two position directional control valve 670, a pilot operated check valve 674, and a relief valve 678. These components are associated with the leveling actuators 542. The support system 654 includes a first permissive valve 682 for extending the support actuator 546, a second permissive valve 686 for retracting the support actuator 546, and a pilot operated check valve 690. These components are associated with each support actuator 546. The enable valves 682 and 686 are two-position directional control valves. The support system 654 will be discussed in detail after describing the leveling system 646.

The proportional valve 662 controls the direction and amount of oil flow into each actuator 542 by allowing precise control of the oil flow into the bore side of the leveling actuators 542. The pressure relief valve 666 maintains a fixed connection between the rod side of the leveling actuator 542 and the main pressure supply. The pressure relief valve 666 sets the equalization pressure, which is used to retract the leveling actuators 542 and lower the mining machine 10 onto its tracks 24 when needed. In one embodiment, the equilibrium pressure is about 20 bar. While the weight of the machine 10 is sufficient to lower the machine 10 when the proportional valve 662 is bleeding off a precise amount of oil, the leveling actuators 542 are lifted off the ground to a retracted position before the machine 10 can be scheduled to perform a mining operation.

When the desired machine position is reached, the leveling actuator 542 is locked in place by the pilot operated check valve 674. The two-position, three-way directional control valve 670 controls oil flow to the proportional valve 662 and also provides pilot pressure to the pilot operated check valve 674. The directional control valve 670 is powered when any adjustment is required and is de-powered once the desired position is reached. The directly operated relief valve 678 limits the downward urging force (i.e., the lifting force) of each actuator 542. The relief valve 678 is set to an optimal pressure value to limit any pressure spikes that may occur during normal or abnormal operation.

The four leveling actuators 542 can be controlled individually or as a whole by remote control. For example, to move a single actuator, an operator may select the corresponding actuator 542 on the robot and actuate the joystick in the desired direction of movement (i.e., up or down).

The continuous mining machine 10 includes a logic controller (not shown) that controls the leveling of the machine 10. As shown in fig. 18, the logic controller includes a leveling selection sequence 700 that selects between a plurality of leveling sequences for the leveling actuators 542. In the illustrated embodiment, the logic controller includes an auto extend sequence 800 (fig. 19), an auto retract sequence 900 (fig. 19), and an individual level sequence 1000 (fig. 20).

Referring to FIG. 18, the leveling selection sequence 700 includes a first step 710 of placing all of the proportional valves 662 and directional control valves 670 in a closed position. The next step 720 places the proportional valve 622 in a neutral position, selects individual or automatic leveling, and selects a direction in which the leveling actuator 542 moves. If the automatic downward direction is selected (step 730), the controller initiates an automatic extend sequence 800 (FIG. 19). If the auto-up direction is selected (step 740), the controller initiates an auto-retract sequence 900 (FIG. 19). If any actuator button indicating individual leveling is selected, the controller initiates an individual leveling sequence 1000 (FIG. 20) when appropriate. The leveling of the mining machine 10 is in this way done automatically by the control system 638 in response to a controller command. In one embodiment, the operator presses a combination of buttons on the remote control device in conjunction with moving the joystick in a desired direction (up or down) to initiate a command sequence to support or not support machine 10.

Upon entering the automatic extension sequence 800, the leveling actuators actuate downward until the physical force between the actuator 542 and the mine surface reaches a predetermined value. Referring to fig. 19, the automatic extend sequence 800 first sets the proportional valve 662 to actuate the leveling actuator 542 (step 810). Each leveling actuator 542 extends at a preset speed and the system determines when each respective headboard 550 engages the mine floor by detecting when the indicator reaches a predetermined value or falls within a specified range of values (step 820). In the illustrated embodiment, the indication is a pressure gradient within the leveling actuator 542. For example, the pressure is monitored using a discrete first derivative of the pressure measured from the pressure sensor 692 of each actuator 542. Since the pressure profile of each actuator 542 during the initial movement is similar to the pressure profile when the headboard 550 engages the ground, the initial movement is ignored for a programmable period of time (step 830).

Once the leveling actuator 542 reaches the mine floor, the leveling actuator 542 is stopped (step 840) and a time delay is activated to allow accurate measurement of the displacement of the actuator 542 (step 850). If the indicated predetermined value is outside the bounds of the maximum stretch length or maximum stretch time, the automatic stretch sequence 800 terminates. If one or more leveling actuators 542 fail to find the ground within a specified time, the extension of all stabilizers 534 stops and the automatic extension sequence 800 terminates. In either case (i.e., if all of the stabilizers 534 contact the ground or if any of the leveling actuators 542 fail), the operator receives an indication, for example, from an indicator light or from a remote control device. If the leveling actuators 542 fail to contact the ground, the operator may individually control the respective actuators 542.

Once all of the leveling actuators 542 engage the ground, the operator can adjust individual leveling actuators 542 from the remote control. If any leveling actuators 542 are manually adjusted, the control system 638 assumes that the machine 10 is not level. An operator may enter a sequence of commands through a remote control to instruct the control system that the machine has been manually leveled and is ready to begin normal operation.

Two parameters affect the sensitivity of the control system 638 to find the ground: 1) the range of indications of physical force between the actuator 542 and the mine surface (i.e., the pressure gradient in the illustrated embodiment) and 2) an amount of time during which the indication is within a specified range. The control system 638 determines whether the leveling actuators 542 have found the floor by measuring the displacement of each actuator 542 and detecting whether both parameters are met. The displacement may be calculated by measuring the amount of time required for actuator 542 to extend to a point where the indication of physical force reaches a predetermined value. The position at which the actuator engages the mine surface is determined by measuring a parameter related to elapsed time or the extension length of the actuator. After the leveling actuators 542 find the ground, each actuator 542 retracts a few millimeters so that the force applied by the individual actuator 542 does not affect the readings of the other leveling actuators 542.

Once each of the four leveling actuators 542 has found the floor and stored the floor position in the memory of the PLC (not shown) of the control system 638, the actuators 542 remain in the "floor found" position for a fixed predetermined period of time (step 860). The leveling actuators 542 are then retracted for a predetermined period of time and then stopped (step 870). Next, the leveling actuators 542 are extended until each actuator 542 reaches the "floor found" position plus the desired offset distance (step 880). If the leveling actuator 542 extends beyond the maximum extension range, the automatic extension sequence 800 is aborted. Once the desired position is reached, the proportional valve 662 is set to the neutral position to stop the leveling actuator 542 (step 890).

The auto-retract sequence 900 is used to un-level the mining machine 10 (i.e., place the machine 10 back onto the tracks 24). As shown in fig. 19, the auto retract sequence includes a first step 910 of actuating the proportional valve 662 to the retract set point. This enables the leveling actuators 542 to simultaneously retract upward (step 920). Once all leveling actuators 542 are in the minimum position, the sequence ends (step 930).

The leveling actuators 542 may be individually lowered to prevent shifting of the center of gravity of the mining machine 10. Referring to fig. 20, the individual leveling sequence 1000 includes a first step 1010 of deactivating all of the leveling actuators 542 and setting the scaled joystick value to neutral. The next step 1020 is to select the direction in which the leveling actuators 542 are moved. Next, the scaled joystick value is calculated for the selected direction (step 1030). The proportional valves 662 are then set to the scaled joystick values and the individual leveling actuators 542 are actuated (step 1040). Once the leveling actuator 542 is leveled, the actuator 542 is stopped (step 1050). This process is repeated until all leveling actuators 542 are leveled.

After leveling the mining machine 10, the support actuators 546 are activated to engage the roof and ensure that the machine 10 is adequately anchored during cutting. In one embodiment, after the leveling sequence is complete, the control system 638 interlocks to allow the support actuators 546 to engage the top in order to prevent damage to the tracks 24 and not necessarily vice versa.

As shown in fig. 21, the controller includes an auto-stabilization sequence 1110 for stabilizing the support actuator 546 against the upper disc or top. The stabilization sequence begins (step 1110) from the idle state (step 1105) and the controller deactivates the first permissive valve 682 and the second permissive valve 686 of each support actuator 546 (step 1120 a). In the illustrated embodiment, the controller reduces fluid flow to zero (step 1120b) and reduces pressure to zero (step 1120 c). The controller then ramps or steps the pressure to the minimum pressure level and the flow to the minimum flow level (step 1130). The controller then determines whether the "up" sequence is selected (step 1140). As described above, the operator can actuate the support actuator 546 by, for example, pressing a combination of buttons on the remote control device in conjunction with moving the joystick in a desired direction (i.e., up or down). During the stabilization sequence 1100, all support actuators 546 are activated simultaneously.

If the ramp up sequence is selected, the controller activates the first enable valve 682 (step 1150) to maintain the set extension speed. In the illustrated embodiment, the controller also unlocks the pilot operated check valve 690, allowing the flow to ramp to a predetermined value or set point (step 1160) and the pressure to ramp to a predetermined value or set point (step 1170).

In the illustrated embodiment, as support actuators 546 extend, the pressure in support actuators 546 is monitored. The control system 638 determines that the headboard 550 has engaged the top when at least one indication of force between the actuator 546 and the top reaches a predetermined value. The indication may include, for example, a pressure in the actuator 546. The control system 638 compares the measured extension time and extension length of the actuator 546 to the maximum allowable extension time and extension length, respectively. That is, if the stabilizer pressure is within the predetermined actuator extension range and has not increased to the preset pressure value within the preset time, the operation times out (step 1175). This causes all stabilizers 534 to stop and the auto-stabilization sequence 1100 to abort.

In the illustrated embodiment, when all of the headboard 550 contacts the top, the controller checks whether the position of the support actuator 546 is within the operating range. If so, an increase is indicated until a predetermined value is reached (step 1180). In the illustrated embodiment, additional pressure is applied until a predetermined pressure set point is reached. The pressure set point is mechanically maintained independent of the control system 638. During an "auto-cut" or "auto-find" control sequence of machine operation, the actuator indications (i.e., pressure and position in the illustrated embodiment) are monitored. If the indication of force between the actuator 546 and the top drops below a predetermined value, the mining machine 510 is considered to be unsupported and all command sequences are aborted. When all support actuators 546 engage the top, the stabilization device 534 automatically re-energizes until the indication of force for each actuator reaches a predetermined value. When the predetermined value is reached in all support actuators 546, the operator receives an indication from, for example, an indicator light or from a remote control device. At this point, other machine operations (such as, for example, "find face" or automatic cutting sequences) may be implemented. Since the full force of the actuators 546 is not applied until all support actuators 546 are in place, the force is evenly distributed over the top.

If the "up" sequence is not selected, the controller determines whether the "down" sequence is selected (step 1240). The "down" sequence may be selected by actuating the remote control (including, for example, moving the joystick downward in combination with pressing other remote control buttons) to retract the support actuators 546. If the "descent" sequence is selected, the controller activates the second enable valve 686 (step 1250) to maintain the set retraction speed. The controller also unlocks the check valve 690. In the illustrated embodiment, this allows the controller to ramp the flow to a predetermined value or set point (step 1260), and then ramp the pressure to a predetermined value or set point (step 1270). The support actuator 546 is then retracted until it has been retracted a predetermined distance (step 1280).

Thus, the invention provides, among other things, a stabilization system for a mining machine. Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described. Various independent features and independent advantages of the invention are set forth in the following claims.