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High gain circular polarized antenna design for harsh mining environments
Kringlen, Collin T.
Kringlen, Collin T.
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2024
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Abstract
Wireless monitoring of bit wear and rock type being mined by mining machines has potential to unlock large improvements in efficiency, cost effectiveness, and safety. Because the mining environment could be unsafe for miners and rough on equipment in the excavation process, routine maintenance is necessary. Through sensor-based measurements on cutting tools, real time data is available to the user allowing them to preemptively determine when maintenance might be needed. This limits work stoppages and prevents equipment from reaching the failure point. Deteriorating equipment can pose risks to both workers and personnel as well as to the machine itself. Furthermore, real time data can help to optimize the excavation process by determining rock types being mined through (rock hardness), cutting speed, as well as other variables. This feature allows the machine to be automated and mine the target material, so called horizon control, and avoid dilution, adding waste material to the target ore, without the need for an operator to be at the face and observe formations.
To have the sensor data available, a wireless communication link must be established to transfer the information from the tools mounted on the cutterhead to the machine. Due to the spinning motion of the machine’s drums or bits, a circular polarized (CP) antenna design is necessary to ensure maximum data transfer from various orientations. The working environment of the antenna is often subject to violent vibrations, dust, debris, and even water. For these reasons, a high gain of at least 6 dB is required for the antennas. A protective antenna cover was also designed for the antennas to avoid the system being damaged. Lastly, the operational frequency of the antennas was set to be 2.44 GHz as it is an unlicensed frequency.
Multiple antenna designs were explored. Through simulation, two designs were chosen and were optimized in a simulation to meet all of the requirements described above. The resulting simulated gain was in the range of 8 to 9 dB. After optimization, two right-hand and two left-hand polarized antennas were fabricated for each design, totaling eight fabricated antennas. The antennas were different in their physical structure which required each antenna to have its own unique protective cover designed. Each fabricated antenna was tested and compared to its corresponding simulated results. This validates the designs and shows they should have adequate performance to enabling transferring cutter head and bit data to the machine control units.
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