Underground mining machine

A system for managing an underground mining machine is disclosed. The system may include a reel-in switch located in an operator station configured to generate plurality of reel-in signals, and a reel-out switch located in the operator station configured to generate a reel-out signal. The system may additionally include an electronic controller in electrical communication with the reel-in switch and the reel-out switch. The electronic controller may be configured to receive the plurality of reel-in signals from the reel-in switch and enter into two or more reeling-in modes in response to the plurality of reel-in signals.

TECHNICAL FIELD

This disclosure generally relates to an underground mining machine and, more particularly, to systems and methods to manage an underground mining machine.

BACKGROUND

Underground mining machines are commonly used around the world to extract minerals, metals and other materials from various hard and soft rock environments. One example of an underground mining machine is a jumbo drill, although many other types exist. The underground mining machine may include a reeling system that may include a power cable coupling a power source for the machine to a working implement of the machine. A cable reel may also be rotatably associated with the underground mining machine and be configured to coil and uncoil the power cable. Further, the reeling system may include a cable reel-motor rotationally engaged with the cable reel. The cable reel-motor may be configured to rotate the cable reel in a first direction when coiling the power cable and rotate the cable reel in a second direction when uncoiling the power cable.

While moving the underground mining machine in a reverse direction, a velocity at which the operator is moving the underground mining machine may be greater than a velocity at which the cable reel-motor is rotating the cable reel. In this instance, the operator may accidentally overrun the power cable, leading to damage and the need to repair or replace the power cable. Additionally, while moving the underground mining machine in a forward direction, and when an amount of the power cable still coiled around the cable reel is nearing its end, the velocity at which the operator is moving the underground mining machine may leave little time for the operator to stop the underground mining machine before breaking the connection between the power cable and the underground mining machine.

Although underground mining machine power cable winding and unwinding schemes are known, there is still room for improvement. For example, U.S. Pat. No. 6,119,837 to Tschurbanoff et al. discloses a hydraulic control system to regulate the rate at which the cable reel winds or unwinds the power cable as a function of machine speed. More specifically, as machine speed increases the mass flowrate of hydraulic fluid sent to a hydraulic motor rotatably engaged with the cable reel increases, and vice versa.

While arguably effective for its specific purposes, such prior art system only attempts to match cable reel speed with underground mining machine speed, failing to recognize a need to operate the underground mining machine in any different manner. Such system also relies on a fluid-based control system, and thus there may be lag between the underground mining machine speed and the cable reel speed, leading to sagging and stretching of the power cable. Also, as a result of such lag, the momentum of the machine may still be great enough that the machine continues to move even after receiving a machine stop signal. In this instance, the power cable may break away from the underground mining machine.

SUMMARY

In accordance with one aspect of the present disclosure, a system for managing an underground mining machine is disclosed. The system may include a reel-in switch located in an operator station configured to generate a plurality of reel-in signals and a reel-out switch located in the operator station configured to generate a reel-out signal. The system may additionally include an electronic controller in electrical communication with the reel-in switch and the reel-out switch. The electronic controller may be configured to receive the plurality of reel-in signals from the reel-in switch and enter into two or more reeling-in modes in response to the plurality of reel-in signals.

In accordance with another aspect of the present disclosure, an underground mining machine is disclosed. The underground mining machine may include a chassis and a motor supported by the chassis. Further, the underground mining machine may include a cable reel rotatably associated with the underground mining machine and the cable reel may be configured to coil and uncoil a power cable. A cable reel-motor may be rotationally engaged with the cable reel, and the cable reel-motor may be configured to rotate the cable reel in a first direction when coiling the power cable, and may further be configured rotate the cable reel in a second direction when uncoiling the power cable. The underground mining machine may additionally include a cable-reel-near-empty-sensor operatively associated with the cable reel and the cable-reel-near-empty-sensor may be configured to generate a reel-near-empty signal when activated. Further, the underground mining machine may include a speed sensor that may be operatively associated with the underground mining machine that may be configured to generate a speed signal. Moreover, the underground mining machine may include an operator station including a reel-in switch configured to generate a plurality of reel-in signals and a reel-out switch configured to generate a reel-in signal. In addition, the underground mining machine may include an electronic controller. The electronic controller may be in electrical communication with the cable reel-motor, the cable-reel-near-empty-sensor, the speed sensor, the reel-in switch and the reel-out switch. The electronic controller may be configured to receive the reel-near-empty signal, the speed signal, the plurality of reel-in signals and the reel-out signal and generate a ccable-reel-out-signal and a cable-reel-in signal in response to at least one of the reel-near-empty signal, the speed signal, the plurality of reel-in signals and the reel-out signal.

In accordance with another embodiment of the present disclosure, a method for managing an underground mining machine is disclosed. The method may include receiving, at an electronic controller located in an underground mining machine, a plurality of reel-in signals from a reel-in switch located in an operator station, and entering, using the electronic controller, a latching reeling-in mode in response to receiving a first reel-in signal from the reel-in switch. The latching reeling-in mode may be configured to limit a reverse direction speed of the underground mining machine to a reverse-direction maximum velocity. Further, the latching reeling-in mode may be configured to receive a speed signal from a speed sensor operatively associated with the underground mining machine and calculate a reverse direction velocity for the underground mining machine. Moreover, the latching reeling-in mode may be configured to generate a cable-reel-in signal while the reverse direction velocity of the underground mining machine is greater than zero and less than or equal to the reverse-direction maximum velocity.

These and other aspects and features of the present disclosure will be more readily understood when read in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE DISCLOSURE

Various aspects of the disclosure will now be described with reference to the drawings, wherein like reference numbers refer to like elements, unless specified otherwise. Referring toFIG. 1, a perspective view of an underground mining machine10is illustrated, according to an aspect of the disclosure. As seen there, the underground mining machine10may include a chassis12supporting an operator station14, a motor16or other power supplying engine and a cable reel18. The chassis12may be supported by wheels20or other ground engaging members such as endless tracks and the like. Further, the underground mining machine10may include a motor control cabinet22wherein some functions of the underground mining machine10may be controlled separately from the operator station14as described in fuller detail below. While the underground mining machine10depicted inFIG. 1is a jumbo drill, the teachings of the present disclosure are not limited to jumbo drills. Rather, the teachings of the present disclosure may find use in many other mining machines such as, but not limited to, an underground mining loader, a continuous mining machine, a longwall mining machine, a flexible conveyor train and the like.

Further, one or more arms24may be operatively connected to the underground mining machine10. Each of the one or more arms24may be operated independently of each other, be articulated and move in three-dimensions. Moreover, a rail26may be operatively engaged with each of the one or more arms24. Each rail26may be slidably engaged with a work implement28such as, but not limited to, a rock drill, a clawed manipulator and the like. The work implement28, being slidably engaged with the rail26, may move between a working position wherein the work implement28is engaging a wall of an underground mine and a retracted position wherein the work implement28is not engaging the wall of the underground mine.

Additionally, the underground mining machine10may include a power cable30extending between the work implement28and a power source32that may couple the work implement28with the power source32. The power cable30may be configured to supply primary or secondary power, such as, but not limited to, electrical, hydraulic or pneumatic power, to the work implement28. The portion of the power cable30associated with the one or more arms24may be of sufficient length to accommodate a full range of motion of the work implement28between the working position and the retracted position. Additionally and alternatively, the portion of the power cable30associated with the one or more arms24may be folded or calendared when the work implement28is moved to the retracted position or when the one or more arms24are moved to a retracted state.

Turning toFIG. 2, a depiction of a reeling system34that may be utilized with the underground mining machine10ofFIG. 1is schematically illustrated. The reeling system34may include the cable reel18previously described. More specifically, however, the cable reel18may be rotatably associated with the underground mining machine10and the cable reel18may be configured to coil and uncoil the portion of the power cable30between the underground mining machine10and the power source32. Further, the reeling system34may include a cable reel-motor36. The cable reel-motor36may be rotationally engaged with the cable reel18. For example, the cable reel-motor36may be rotationally engaged with the cable reel18by a shaft38. When the cable reel-motor36is activated, it may rotate the cable reel18in a first direction40when coiling the power cable30about the cable reel18and rotate the cable reel18in a second direction42when uncoiling the power cable30from the cable reel18.

Turning now toFIG. 3, a diagram of a control system44for managing the underground mining machine10is depicted. As illustrated there, the control system44may include a reel-in switch46configured to generate a plurality of reel-in signals48when actuated. In one embodiment the reel-in switch46is located in the operator station14described above. However, this is only exemplary as it is contemplated that the reel-in switch46may be located at other locations of the underground mining machine10, such as, but not limited to, the motor control cabinet22previously discussed. Further, the control system44may include a reel-out switch50configured to generate a reel-out signal52when actuated. In one embodiment the reel-out switch50is located in the operator station14previously discussed Like the reel-in switch46, however, this location is only exemplary as the reel-out switch50may be located at other locations of the underground mining machine10including the motor control cabinet22.

Further, as depicted, the control system44may include an electronic controller54that is in electrical communication with the reel-in switch46and the reel-out switch50. Further, as is shown, being in electrical communication with the reel-in switch46and the reel-out switch50, the electronic controller54may be configured to receive the plurality of reel-in signals48and the reel-out signal52. For example, as represented, the electronic controller54may include a receiver module56configured to receive the plurality of reel-in signals48and the reel-out signal52. Moreover, while the electronic controller54is represented as being a standalone device, it may be integrated into the electronic control module (ECM) or electronic control unit (ECU) of the underground mining machine10. Furthermore, the electronic controller54may be implemented using any one or more of a processor, a microprocessor, a microcontroller, a field programmable gate array (FPGA), a programmable read-only member (PROM), application specific integrated circuit (ASIC) or any other device that can be operated in accordance with preprogrammed instructions and/or algorithms disclosed herein.

Further, as shown, the control system44may include a speed sensor58configured to generate a speed signal60. The speed sensor58may be operatively associated with the underground mining machine10. More specifically, however, the speed sensor58may be operatively associated with the wheels20, endless track or other ground engaging members, of the underground mining machine10and be configured to measure an angular velocity of the wheels20, endless track or other motive device, in order to generate the speed signal60. The foregoing is only an example, as the speed sensor58may also be located anywhere on the underground mining machine10where the speed sensor58may generate the speed signal60. For example, the speed sensor58may be located in the operator station14described above and utilize signals from multiple local-area network (“LAN”) nodes located in an underground mine to generate the speed signal60. In addition, besides the plurality of reel-in signals48and reel-out signal52, the receiver module56may also be configured to receive the speed signal60.

When the receiver module56of the electronic controller54receives the plurality of reel-in signals48from the reel-in switch46, the receiver module56may pass the plurality of reel-in signals48to a comparator module62. Once in the comparator module62, the electronic controller54may determine whether the plurality of reel-in signals48generated by the reel-in switch46is a first reel-in signal64or a second reel-in signal66. For example, the comparator module62may apply a timer to the plurality of reel-in signals48received from the reel-in switch46and determine that the plurality of reel-in signals48is a first reel-in signal64because the comparator module62received the plurality of reel-in signals48for more than a minimum amount of time. Alternatively, the comparator module62may apply a timer to the plurality of reel-in signals48received from the reel-in switch46and determine that the plurality of reel-in signals48is a second reel-in signal66because the comparator module62received the plurality of reel-in signals48for less than or equal to a minimum amount of time. However, these are only examples since the reel-in switch46may further be configured to generate different signals. For example, the reel-in switch46may generate a saw-tooth signal in order to generate the first reel-in signal64and a square-wave signal to generate the second reel-in signal66, or vice versa for that matter.

In response to the plurality of reel-in signals48, the comparator module62may determine whether or not to enter into a latching reeling-in mode68. More specifically, if the comparator module62receives the first reel-in signal64the electronic controller54may enter into a latching module70thereby entering into latching reeling-in mode68. Further, while in the latching module70the electronic controller54may be further configured to receive the speed signal60from the speed sensor58and limit the speed of the underground mining machine10to a reverse-direction maximum velocity119. For example, while in this mode, the reverse-direction maximum velocity119of the underground mining machine10may be limited to one kilometer per hour (“KPH”), two KPH, three KPH, four KPH, five KPH, six, KPH, seven KPH, eight KPH, nine KPH, ten KPH or even greater. Further, while in the latching reeling-in mode68, the electronic controller54may be further configured to receive the speed signal60from the speed sensor58, calculate the velocity of the underground mining machine10and generate a cable-reel-in signal74while the velocity of the underground mining machine10is greater than zero KPH and less than or equal to the reverse-direction maximum velocity119. In response, the cable reel-motor36may receive the cable-reel-in signal74and rotate the cable reel18in the first direction40.

Additionally, the control system44may include a cable-reel-full-sensor76operatively associated with the cable reel18. The cable-reel-full-sensor76may be configured to generate a reel-full signal78when activated, such as when the portion of the power cable30between the underground mining machine10and the power source32is fully coiled around the cable reel18. The electronic controller54may be in electrical communication with the cable-reel-full-sensor76and be configured to receive the reel-full signal78, such as by the receiver module56. Furthermore, while in the latching reeling-in mode68, the electronic controller54may be further configured to stop generating the cable-reel-in signal74in response to the reel-full signal78.

The control system44may also include a parking brake sensor80operatively associated with the underground mining machine10. More specifically, the parking brake sensor80may be operatively associated with a parking brake and be configured to generate a brake-on signal82when activated, such as when an operator applies the parking brake. The electronic controller54may be in electrical communication with the parking brake sensor80and be configured to receive the brake-on signal82. Moreover, while in the latching reeling-in mode68, the electronic controller54may be further configured to stop generating the cable-reel-in signal74in response to the brake-on signal82.

In addition, the control system44may include a direction sensor84operatively associated with the underground mining machine10. The direction sensor84may be configured to generate a reverse signal86when the underground mining machine10is moving in a reverse direction, such as when coiling the power cable30. Alternatively, the direction sensor84may be configured to generate a forward signal88when the underground mining machine10is moving in a forward direction, such as when uncoiling the power cable30. In one instance, the direction sensor84may be operatively associated with a gear selector configured to choose between a forward gear and a reverse gear for the underground mining machine10. In another instance, the direction sensor84may be associated with a transmission of the underground mining machine10. Nevertheless, the electronic controller54may be in electrical communication with the direction sensor84and may be configured to receive the reverse signal86and the forward signal88. Moreover, while in the latching reeling-in mode68, the electronic controller54may be further configured to stop generating the cable-reel-in signal74when the electronic controller54stops receiving the reverse signal86.

Furthermore, in additional aspects of the current invention, while in the latching reeling-in mode68, the electronic controller54may stop generating the cable-reel-in signal74when it again receives the plurality of reel-in signals48from the reel-in switch46. Alternatively, and while in the latching reeling-in mode68, the electronic controller54may stop generating the cable-reel-in signal74in response to receiving the reel-out signal52.

Moving on, in response to the plurality of reel-in signals48, the comparator module62may determine whether or not to enter into a non-latching reeling-in mode90. More specifically, if the comparator module62receives the second reel-in signal66the electronic controller54may enter into a non-latching module92thereby entering into the non-latching reeling-in mode90. Further, while in the non-latching reeling-in mode90the electronic controller54may be configured to generate the cable-reel-in signal74only while it receives the second reel-in signal66from the reel-in switch46.

Still referring toFIG. 3, when the electronic controller54receives the reel-out signal52from the reel-out switch50, it may generate a ccable-reel-out-signal94while receiving the reel-out signal52. In response, the cable reel-motor36may receive the ccable-reel-out-signal94and rotate the cable reel18in the second direction42. Furthermore, the control system44may additionally include a cable-reel-near-empty-sensor96operatively associated with the cable reel18. The cable-reel-near-empty-sensor96may be configured to generate a reel-near-empty signal98when activated, such as when the length of the power cable30coiled around the cable reel18is nearing its end.

The electronic controller54may be in electrical communication with the cable-reel-near-empty-sensor96and be configured to receive a reel-near-empty signal98. In response, the electronic controller54may enter into a speed-limiting reeling-out mode100. More specifically, the electronic controller54may enter into a speed limiting module102thereby entering into the speed-limiting reeling-out mode100. While in the speed-limiting reeling-out mode100, the electronic controller54may be further configured to receive the speed signal60from the speed sensor58and limit the speed of the underground mining machine10to a forward-direction maximum velocity127. While in this mode, the forward-direction maximum velocity127of the underground mining machine10may be limited to one KPH, two KPH, three KPH, four KPH, five KPH, six, KPH, seven KPH, eight KPH, nine KPH, ten KPH or even greater. The forward-direction maximum velocity127in the speed-limiting reeling-out mode100may be the same as, or different, than the reverse-direction maximum velocity119when the underground mining machine10is in the latching reeling-in mode68. Furthermore, while in the speed-limiting reeling-out mode100, the electronic controller54may be configured to calculate the velocity of the underground mining machine10and generate the ccable-reel-out-signal94while the velocity of the underground mining machine10is greater than zero KPH and less than or equal to the forward-direction maximum velocity127.

The control system44may also include a cable-reel-empty sensor104operatively associated with the cable reel18. The cable-reel-empty sensor104may be configured to generate a reel-empty signal106when activated, such as when the length of the power cable30coiled around the cable reel18is at its end. Furthermore, the electronic controller54may be in electrical communication with the cable-reel-empty sensor104and be configured to receive the reel-empty signal106. While in the speed-limiting reeling-out mode100, the electronic controller54may be further configured to stop generating the ccable-reel-out-signal94in response to the reel-empty signal106. Moreover, while in the speed-limiting reeling-out mode100, the electronic controller54may be further configured to generate a machine stop signal108in response to the reel-empty signal106. As seen inFIG. 3, the underground mining machine10may receive the machine stop signal108, thereby stopping movement of the underground mining machine10.

Furthermore, as described above, the electronic controller54may be in electrical communication with the direction sensor84. While in the speed-limiting reeling-out mode100, the electronic controller54may be configured to receive the forward signal88and stop generating the ccable-reel-out-signal94when it stops receiving the forward signal88.

INDUSTRIAL APPLICABILITY

In general terms, the present disclosure may find applicability in many industries including, but not limited to, underground mining, and more particularly, to systems and methods for managing power cabling of underground mining machines. Although applicable to any underground mining machine10, the present disclosure may be particularly applicable to an underground mining machine10including the reeling system34having the cable reel18rotatably associated with the underground mining machine10configured to coil and uncoil the power cable30.

In general, the present disclosure employs the reel-in switch46, the reel-out switch50, the electronic controller54and numerous sensors (such as the speed sensor58, cable-reel-full-sensor76, cable-reel-near-empty-sensor96and cable-reel-empty sensor104) to limit the velocity of the underground mining machine10to the reverse-direction maximum velocity119when coiling the power cable30around the cable reel18and to the forward-direction maximum velocity127when uncoiling the power cable30from the cable reel18, thereby mitigating damage to the power cable30. More specifically, when coiling the power cable30, the underground mining machine10may enter into the latching reeling-in mode68that only coils the power cable30when the velocity of the underground mining machine10is greater than zero KPH and less than or equal to the reverse-direction maximum velocity119. Further, when uncoiling the power cable30, the underground mining machine10may enter into the speed-limiting reeling-out mode100that only uncoils the power cable30when the velocity of the underground mining machine10is greater than zero KPH and less than or equal to the forward-direction maximum velocity127. Limiting the velocity of the underground mining machine10, instead of matching the speed of the cable reel18to the underground mining machine10, reduces the chance that the underground mining machine10will overrun the power cable30during coiling and additionally mitigates the likelihood that the power cable30breaks away from the underground mining machine10during uncoiling.

One exemplary algorithm or electronic controller implemented method110for managing an underground mining machine10is diagrammatically provided inFIG. 4. As shown, the electronic controller54may be configured to continuously, periodically or intermittently receive the plurality of reel-in signals48from the reel-in switch46and the reel-out signal52from the reel-out switch50at block112. In block114, the electronic controller54may determine whether the signals received are the plurality of reel-in signals48. If the signals received are the plurality of reel-in signals48then the electronic controller54may determine whether the first reel-in signal64has been received at block116and enter into the latching reeling-in mode68at block118. The latching reeling-in mode68may be configured to limit a reverse direction speed of the underground mining machine10to a reverse-direction maximum velocity119, receive the speed signal60from the speed sensor58operatively associated with the underground mining machine10, calculate a reverse direction velocity for the underground mining machine10and generate the cable-reel-in signal74only while the reverse direction velocity of the underground mining machine10is greater than zero KPH and less than or equal to the reverse-direction maximum velocity119. If however the second reel-in signal66is received instead, then the electronic controller54may enter into the non-latching reeling-in mode90at block120. In the non-latching reeling-in mode90, the electronic controller54may be configured to generate the cable-reel-in signal74only while receiving the second reel-in signal66.

Returning to block114, if the electronic controller54did not receive the plurality of reel-in signals48, then the electronic controller54may determine if it has received the reel-near-empty signal98at block122. If the electronic controller54has not yet received the reel-near-empty signal98then it may generate a ccable-reel-out-signal94at block124. However, if the electronic controller54has received the reel-near-empty signal98, then it may enter the speed-limiting reeling-out mode100at block126. The speed-limiting reeling-out mode100may be configured to limit a forward direction speed of the underground mining machine10to a forward-direction maximum velocity127, receive a speed signal60from the speed sensor58operatively associated with the underground mining machine10, calculate a forward direction velocity for the underground mining machine10and generate the ccable-reel-out-signal94only while the forward direction speed of the underground mining machine10is greater than zero KPH and less than or equal to the forward-direction maximum velocity127.

The above description is meant to be representative only, and thus modifications may be made to the embodiments described herein without departing from the scope of the disclosure. Thus, these modifications fall within the scope of present disclosure and are intended to fall within the appended claims.