Imaging-based interface sensor and control device for mining machines

• US 9,650,893 B2
• Filed: 04/01/2011
• Issued: 05/16/2017
• Est. Priority Date: 04/01/2011
• Status: Active Grant

• Current Assignee: Joy Global Underground Mining LLC (Komatsu Ltd.)
• Original Assignee: Joy Mm Delaware Incorporated (Komatsu Ltd.)
• Inventors: Herdle, David Kevin
• Primary Examiner(s): Troost, Aaron L
• Application Number:
  US13/078,660
• Publication Number:
  US 20120253584A1
• Time in Patent Office: 2,237 Days
• Field of Search: 701 28, 701523, 299 105, 299 11, 299 29
• CPC Class Codes: E21C 25/06 Machines slitting solely by one or more cutting rods or cutting drums which rotate, move through the seam, and may or may not reciprocate
• CPC Class Codes: E21C 27/02 solely by slitting rods, drums, for same E21C25/10; saws, discs, wheels E21C25/18; chains, chain guides, for same E21C25/28
• CPC Class Codes: E21C 27/10 by both slitting and breaking-down
• CPC Class Codes: E21C 27/24 by milling means acting on the full working face , i.e. the rotary axis of the tool carrier being substantially parallel to the working face similar machines for tunneling E21D9/1026
• CPC Class Codes: E21C 35/08 Guiding the machine
• CPC Class Codes: E21C 35/24 Remote control specially adapted for machines for slitting or completely freeing the mineral control in general G05
• CPC Class Codes: G06T 7/13 Edge detection

Abstract

Systems, methods, and computer-readable medium containing instructions for controlling mining machines. One system includes an image sensor for capturing an image of a cutting face of a mine and interface sensing and control system for obtaining the image, identifying an anomaly in the image, calculating a distance between the anomaly and a reference, and using the distance to automatically instruct a mining machine control system to keep a cutter head of the mining machine within a seam.

Claims

1. A system for controlling a mining machine, the system comprising:

an image sensor for capturing an image of a cutting face of a mine;

an interface sensing and control system for obtaining the image, identifying an anomaly in the image by comparing the image to a plurality of images of known anomalies, calculating a distance between the anomaly and a reference using a known distance between the image sensor and the cutting face and a known size of pixels in the image, and using the distance to automatically instruct a mining machine control system to keep a cutter head of the mining machine within a seam.

2. The system of claim 1, wherein the interface sensing and control system identifies the anomaly in the image by identifying a band in the image.

3. The system of claim 2, wherein the band includes a clay band.

4. The system of claim 2, wherein the band includes a rock band.

5. The system of claim 1, wherein the reference includes at least one of a roof of the mine and a floor of the mine.

6. The system of claim 1, wherein the reference includes a marker placed in the mine.

7. The system of claim 1, wherein the interface sensing and control system uses the distance to instruct a mining machine control system to keep a cutter head of the mining machine within a seam by comparing the distance between the anomaly and the reference and a distance between the cutter head and the reference.

8. The system of claim 1, wherein the interface sensing and control system provides the image to an operator.

9. The system of claim 1, wherein the interface sensing and control system provides the distance to an operator.

10. The system of claim 1, wherein the image sensor includes a video camera.

11. The system of claim 1, wherein the image sensor includes a still camera.

12. The system of claim 1, wherein the image sensor includes a thermal camera.

13. A computer-implemented method for controlling a mining machine, the method comprising:

obtaining an image of a cutting face of a mine with an image sensor;

identifying an anomaly in the image by comparing the image to a plurality of images with known anomalies;

calculating a distance between the anomaly and a reference using a known distance between the image sensor and the cutting face and a known size of pixels in the image; and

using the distance to automatically keep a cutter head of the mining machine within a seam.

14. The method of claim 13, wherein identifying an anomaly in the image includes identifying a band in the image.

15. The method of claim 14, wherein identifying the band includes identifying a clay band in the image.

16. The method of claim 14, wherein identifying the band includes identifying a rock band in the image.

17. The method of claim 13, wherein calculating the distance includes calculating a distance between the anomaly and at least one of a roof of the mine and a floor of the mine.

18. The method of claim 13, wherein calculating the distance includes calculating a distance between the anomaly and a marker placed in the mine.

19. The method of claim 13, further comprising providing the image to an operator.

20. The method of claim 13, further comprising providing data about the anomaly to an operator.

21. The method of claim 13, wherein using the distance to keep a cutter head of the mining machine within a seam includes comparing the distance between the anomaly and the reference and a distance between the cutter head and the reference.

22. Non-transitory computer-readable medium encoded with a plurality of processor-executable instructions for controlling a mining machine having a cutter head, the instructions comprising:

obtaining an image of a cutting face of a mine with an image sensor;

identifying an anomaly in the image by comparing the image to a plurality of images of known anomalies;

calculating a distance between the anomaly and a reference based on a known distance between the image sensor and the cutting face and a known size of pixels in the image; and

using the distance to automatically keep a cutter head of the mining machine within a seam.

23. The computer-readable medium of claim 22, wherein the instructions for identifying the anomaly include instructions for identifying the anomaly in the image using edge-detection technology.

24. The computer-readable medium of claim 22, wherein the instructions for calculating the distance includes instructions for calculating a distance between the anomaly and at least one of a roof of the mine and a floor of the mine.

25. The computer-readable medium of claim 22, wherein the instructions for calculating the distance includes instructions for calculating a distance between the anomaly and a marker placed in the mine.

26. The computer-readable medium of claim 22, wherein the instructions for using the distance to keep a cutter head of the mining machine within a seam include instructions for comparing the distance between the anomaly and the reference and a distance between the cutter head and the reference.