Sebastian Mundry - Caterpillar Global Mining - Supporting toolsets for efficient and productive...

Supporting Toolsets

for

Efficient & Productive

Longwall Operation

Dr. Sebastian Mundry

CATERPILLAR GLOBAL MINING

Hunter Valley – October 26-27 th, 2015

2 // 14th LONGWALL CONFERENCE - Hunter Valley // Caterpillar Confidential: GREEN

Outline of the Presentation

What is Needed for Efficient and Productive Longwall Operation?

Indirect Supporting Toolsets

Cat® MineStar™ capability set “Health for Longwall”

Equipment Care Advisor (ECA)

Direct Supporting Toolsets

VFD Technology for Plow & Conveyor Systems

Cat® MineStar™ capability set “Command for Longwall“

Featuring LongwallNavigator

Realization of Benefits in Known Environment & Installations

Conclusion


Efficient and Productive Longwall Operation

Longwall mining

… is an expensive undertaking, from the preparation of the site itself to capital investment in the equipment.

Longwall owners

… have extremely high performance expectations—especially in tough economic times when commodity prices are low.

Longwall mines

… should achieve or even exceed their owners’ expectations through the extensive use of automation.

With Indirect and Direct Toolsets.


Efficient and Productive Longwall Operation

What is Needed ?

A. General Requirements:

Robust high performing Longwall Equipment (Shearer / Plow, Roof Supports, Conveyor system, Belt system)

Appropriate mining conditions

Motivated crew, well trained on individual responsibilities

B. Indirect Supporting Toolsets:

Condition Monitoring and Analysis Tools and Services for all equipment in operation allowing corrective and proactive actions

Combined with supportive and advising business partner - 24/7

C. Direct Supporting Toolsets:

Reliable automation at a sufficient level

for all equipment in operation and

the interactions of this equipment

INDIRECT

SUPPORTING

TOOLSETS

6 // AIMS 2015 RWTH AACHEN // Caterpillar Confidential: GREEN

Structure of 8 Product Levels

LEVEL 8

LEVEL 7


Product Landscape

Cat® MineStar™ System


Longwall Capabilities


• Vibration Analysis (VibraGuard®)

• V-Software like VShield, VDrive, VShearer, VPlow, VBSL, VBootEnd, VGraph3D, etc.

• VLongwall Database

• MineStar Reports

• Personnel

• HD & DomeCamera

• Camera S/W

• Shearer Tracking

• 3D Face Visualization

• Longwall Navigator

• Plow System Control Cab


Health for Longwall

Latest Released Toolsets

Health for

Longwall

Vibration

Analysis

V VFDfor Plow

V VFDfor AFC

Longwall

Web View


Caterpillar developed web-based application combining:

equipment and application information

with advanced analytics and

dealer interpretive expertise

that results in an improved ability for dealers and customers to

make informed maintenance, repair or component replacement decisions

The application integrates and correlates

condition monitoring data,

utilizes advanced analytics,

incorporates Caterpillar and Dealer global knowledge sharing,

provides recommendation management, and

value tracking

Cat Equipment Care Advisor Protect

(Cat ECA-Protect)


ECA - Equipment Care Advisor

Turning Equipment Data into Actionable

InformationGlobal Customer Supporting Technology

Traditional Cat Equipment


Caterpillar CPI Organization

Cat Dealer

Caterpillar Engineering

VSoftwareSurface

Caterpillar Condition Monitoring Service

CustomerMine Site

Provide

Service &

Reports

CaterpillarData Warehouse / “Cloud”

(GIS, Peoria)

Longwall

Equipment

Data Transfer Site Server

ECA - Equipment Care Advisor

PL Longwall Perspective


Electronic Data

• Vibration Analysis (VibraGuard®)

• V-Software like VShield, VDrive, VShearer, VPlow, VBootEnd, VGraph3D, VBSL, Vchain Tensioner

• VLongwallDatabase

• MineStar Reports

• VshieldPerformance

Inspections

• Spreadsheets

• Portal

• “Smart Device”

• Cat Inspect

• iPad/iPhone

• Droid

Fluids

•Cat® S.O.SSM

Services

•3rd Party

Machine History

• ERP / Work order system

• Warranty

• AS Built information

• Machine Specification data

• Component Life Data

Site Conditions

• Geology

• Wear rate

• Production plans

• Adverse conditions

• Mining method

Data Sources – Five Elements of

Condition Monitoring


CustomerMine Site

Cat DealerCaterpillar

ECA or Health for Longwall

Choice of Toolset depending of Initiatives

Health for LongwallVLongwallData & Reports Initiative at

Customer only1

Health for LongwallVLongwallData & Reports

Initiative at

Customer &

Dealer

2 Initiative at

Dealer mainly

ECA & Reports

Collect data

Provide service

3

DIRECT

SUPPORTING

TOOLSETS



LEVEL 8

LEVEL 7



VFD Technology for Conveyor and Plow Systems

Air cooled unit Water cooled unit

GM3 ~

Data - Link

Frequency Converter

Speed sensor AC Motor Gear Box AFC / Plow

Mains

Voltage source converters

Current source converter

L1

L2

L321

1

2


VFD Drives

Technical Features

Remote Parameter settings

in dependence of particular application

Remote operation from

Gate End and / or Surface

4 quadrant operation

(regeneration function)

Cable length up to 4000m

(allow to cross whole face by cable)

External encoder interface for real time speed feedback

based on fibre optic data link

Controlled chain force reduction

in case of blockades or chain cracks

Total torque control at zero speed => allow further feature without

add. components (chain tensioning without auxiliary motor)


VFD Container

Each drive of the face conveyor system requiresone air-cooled and one liquid-cooled VFD station(connected to a separate dual circuit cooling station)

Separate CoolingStationTwo Drives at Maingate

Drive at Tailgate

Cable Distance betweenVFDs and AFC drives: up to 4km (2.5 miles)

Application:

Drives for Conveyor Systems


Application:

Drives for Plow Systems

Preferred mining procedure

for seam hights below 1,8 m

For mid and low seams in the range

of 0.8 m – 2.3 m seam height

High Speed of up to 3,6 m/s

Highest available

Drive Power: 2 x 800 kW

Max. production per hour: 3.500 tons

1.8 m2.3 m

Co

al s

eam

th

ickn

ess

[m

]

Shearer

Plow

Low operational costs

Fully automated Plow Systems

Command functionality available


Synchronicity and Precision

=> Utilization of the Full Installed Power

High and constant torque possible throughout the entire speed

range from 0 to maximum speed

Full utilization of installed power on both plow / conveyor

motors through load shearing

Intelligent and continuous torque and speed control function

(Master = speed controlled, Slave = torque controlled)

Synchronized startup of all drives at full load

(with or without CST)

Flexible control concepts / algorithms according to mining process

and stage

Comprehensive and flexible

parameter setting

for torque and speed


Customer Benefit:

Low Life Cycle Costs and High Availability

No limitation of start up cycles per time

interval

Reduction of impact of drive system on chains,

line pans and chain sprockets

Reduced impact on hardware in case of

blockades or chain cracks

Improvement of overload protection for motors

and chains

Early detection of chain break

allows controlled shut down

=> Less wear => Less damages

=> Reduced down time & effort

=> Reduced cost


Command for Longwall

Plow Control Rooms

Underground

At Surface


Life Data From VPlow

(a Health for Longwall Product)

Life dataFrom VPlow

(a Health for Longwall product)

Plow position

Plow Speed

Torque MG / TG

Motor Speed

Motor PowerMG / TG



LEVEL 8

LEVEL 7



Main Elements: SRB and LongwallNavigator

SRB - Shearer Random Batch

= RSC (Roof Support Control) supported Automation of Roof Supports allowing man less shield cycle (lower, advance and set) and full conveyor push, accompanied by several miner automation functions like spray water pattern, side shield operation, etc.

LongwallNavigator:

= 3D control of Shearer cutting operation, supported by onboard IMU and different onboard and gate end S/W tools providing 100% detection of conveyor profile and accurate ranging arm steering, accompanied by SBA (State Based Automation) and other miner Shearer automation functions. *)

Where applicable - TCC (Top Coal Caving) Automation:

= RSC supported automation of caving shields and doors. Rear AFC control automation.

*) As at the date of creation of this document, the intellectual property rights in the LASC technology

(Interconnection of Landmark Compliant Longwall Mining Equipment-Roof Support System

Communication) are owned by the Commonwealth Scientific and Industrial Research Organization.

LASC technology is used and distributed by Caterpillar under license.



LongwallNavigator (Version 1)

Horizon Control

Plane

Extraction Control

Plane

Face Alignment

Plane

3 Main Elements of LongwallNavigator:

Extraction Control & Horizon Control & Face Alignment


Extraction Control

@ LongwallNavigator

“Extraction Control” allows the machine to mine defined floor and roof profiles along the face to follow given a coal seam undulations for optimal extraction and production.

PanCoal Face

g Gravity

Roof profile

Pan profileFace View

PanPan


Extraction Control

Improvement of Profiling During Enrolment

Change of floor profiles over 3 months during enrolment of shearer automation.Herby the degree of automation was increased in two major steps and the periods of manual override were constantly reduced.

Enhancement of

Software Functionality

Regular operation

in automation mode

Manual Mode


Extraction Control

Example Extraction Profile

Shear 10 – 12:02pm - Third Shear in Auto - MG to TG

-1000

0

1000

2000

3000

4000

5000

6

13

20

27

34

41

48

55

62

69

76

83

90

97

10

4

11

1

11

8

12

5

13

2

13

9

14

6

15

3

16

0

16

7

17

4

18

1

18

8

19

5

20

2

20

9

21

6

22

3

23

0

23

7

24

4

25

1

25

8

26

5

27

2

27

9

28

6

LH Manual

LH Over

LH Auto

RH Man

RH Over

RH Auto

Manual Operation

Cu

ttin

g H

eigh

t [m

m]

Face Length [m]


Extraction Control

Face Wide Usage of Automation Mode

% of Automation 5 th to 13th Sept. 2014

Face Length [m]


Coal

Seam

Horizon Control

@ LongwallNavigator

Face Advance Tilt (FAT) Side View

In parallel to “Extraction Control” the “Horizon Control” guides the machine to follow the seam undulations in advance direction e.g. to follow a given constant Face Advance Tilt (FAT).

g Gravity


Horizon Control

Automatic correction of a introduced height change with regard to machine roll angle to keep target FAT.


Horizon Control – Example of Operation

Machine Roll (FAT) over Face Length and Time

Target: Zero Degree Horizon

Height changes for

profile correction

causing roll changes

Setting new target line


Coal Seam

Pan line

Face Alignment

@ LongwallNavigator

“Face alignment” keeps face conveyor straight or in a defined shape all the time of operation for consistent production and minimal wear of the conveyor system.

Top View

Pan

RS

Pan

RS

Pan

RS

Pan

RS

Pan

RS

Pan

RS

Pan

RS

g Gravity

Ad

va

nc

e

dir

ecti

on


Face Alignment

Before Alignment Alignment in process

Realization of Benefits

in Known

Environment &

Installations


Realize the cultural change!

All mine personnel need to be striving for improvements as a culture

Get crew well trained

Get crews focused on total mine conditions instead machine conditions only

Usage of Indirect Toolsets for continuous improvement

Regularly review operations

The targeting for efficiency and improvement must never end

Make crew trust in automation:

Change the culture

From: “I better operate manual!”(suppress automation to often)

To: “Will I really be better?“(request for manual override at foreman)

Lesson’s Learned

When Realizing the Benefits


Personnel Needed to Operate a Sherarer Longwall

(Australian Operations)

Level of Automation

Highly automated longwall

Highly automated longwall

Low degree of automation (installed or used)

Mining conditions

Well manageablemining conditions

Difficult mining conditions or difficult miningstyle

Manageable mining conditions

Main Automation Features used

SRBand LongwallNavigator

Part time SRB

Personnel needed at face

6-7 miner

6-7 + 5-10 miner

12-16 ++ miner


Highly Automated Longwall

Role of Personnel (Australia Operations)

Opertor at face Explanation of role

1. Deputy Safety Man, monitoring safety conditions at face

2. Longwall CoordinatorForeman, coordinating production progress and actions

3. Shearer operatorAccompanies Shearer at fresh air side, interacts only if necessary

4. Shield operatorAccompanies automated shield advance, interacts only if necessary

5. Electrical engineer Carry out electrical maintenance

6. Mechanical engineer Carry out mechanical maintenance

(7. Boot End Operator) Care for smooth boot end operation


Automation Utilization Shearer Longwall

(Australian Operations)

Color Legend:

Green = Automation

(Idle method)

Yellow = Automation

(Previous

Reference

Extraction)

Blue = Drum Override mode

Purple = Manual mode

Floor Drum Mode

Roof Drum Mode


Personnel Needed to Operate a Plow Longwall

(Europe Operations)

Nobody needs to be at face,

when the plow is running

Tail

drive

Main

driveGob

coal face

Rectangular gate-roads:

1 supervisor

5 operators

4 maintenance

= 10

Arch support gate-roads:

1-2 supervisors

3-4 MG operators

2-4 TG operators

4-6 maintenance

= 10 - 16


Production Rate - Plow Longwall

(Poland Operations)

Face length: 247 m - Seam thickness: 1.8 m - Specific gravity: 1.8 t/m³

CONCLUSION


Direct benefits regarding operation

High automation allows predictable and continuous productivity

=> Even machine load

=> Reduce wear & reduce components damage

=> Less costs

=> Predictable maintenance intervals

Exact production performance adaptation to planned mine production

Benefits regarding Personnel

Get operator out of the dust area - operate from fresh weather side only

Reduced exposure to operation hazards at face

Reduced personnel needed at operation area

Changed skillset of operator crew - reduced pressure on operator skills

Conclusion

Benefits for the Longwall Business


Conclusion:

Span of requirements needed to be fulfilled

High performing Longwall Equipment

Appropriate mining conditions

Well trained and motivated crew

Continuous usage of Direct and Indirect Toolsets provide by Caterpillar

Realize cultural change in operation

Reducing human interaction with equipment for significant periods off operation

Efficient and Productive Longwall Operation can be reached

=> Allow Mines to stay competitive in challenging economical times

=> Best Total Cost of Ownership

Outlook: Migrate customer fleet to ECA (2016 ff.) LongwallNavigator 2&3: Move from “Target Line Commands” to “Target Volumes” Get ready for Autonomous Longwall Operation

Conclusion and Outlook

Hunter Valley – October 26-27 th, 2015

CATERPILLAR GLOBAL MINING

Thank you

for your attention!

and as Germans say:

Glückauf!

Sebastian Mundry - Caterpillar Global Mining - Supporting toolsets for efficient and productive...

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