Advancing unmanned roadheader-based tunneling: a framework for challenging underground environments

Unmanned roadheader-based tunneling in complex underground environments represents a significant advancement in mining technology, offering the potential to enhance safety and efficiency, but it poses considerable challenges in terms of precise control, navigation, and real-time decision-making. In response to these challenges, we have developed a comprehensive framework that integrates software, communication protocols, hardware, and newly developed algorithms. The proposed system architecture employs a laser-based total station for high-precision surveying, coupled with a programmable logic controller (PLC) integrated with multiple sensors to control the movement of the roadheader. To resolve key issues such as command issuance, robust positioning, autonomous navigation, real-time visualization of the working face, and trajectory planning for both the roadheader and cutter head, specialized algorithms have been developed. These components are integrated into a client/server software system, which includes a user-friendly interface that ensures efficient and safe tunneling operations. The client, deployed remotely, generates, and delivers operational instructions while providing real-time visualization of the working face, whereas the server, stationed on-site, executes these instructions, and ensures precise control and positioning of the roadheader. Comprehensive experimentation and system deployment have demonstrated the framework’s effectiveness, successfully resolving key issues such as accurate positioning, unmanned navigation, cutting control, and multiple-trajectory planning. This system not only facilitates successful unmanned tunneling but also offers substantial benefits to the mining industry in China, with potential applications in other unmanned tunneling machines and civil construction projects.