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Longwall Automation

Longwall Automation
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Longwall Automation

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Unparalleled Control Excellent automation is the basis for the success of a longwall – the quality and reliability of the automation system are key factors in the success of the operation. Caterpillar is the only manufacturer that is able to provide a complete modular family of powerful controllers that integrate fully with Cat® longwall equipment. This means one-stop shopping, no interfacing problems and products customized to your needs. Full Range, Full Integration Design Criteria Based on the successful Cat PM4 series, the PMC™ family is a new generation of controllers designed to meet...

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Benefits The integration of the various machines (plow or shearer, AFC, and roof supports) allows optimal tuning of the complete system. This results in numerous benefits for the user, including: •• Full utilization of plow, shearer and AFC capacity •• Protection of the system from overload •• Minimized chain downtime, extended service life of drives •• ptimization of chain tension, dependent on load, O for all load conditions •• Maximum possible startup torque for heavy-load start •• achine speed adjusted to the conveyor load, no M overload of system Roof supports •• Timely movement of...

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The communication within the PMC™ family is based on a field bus system The PMC™ Family A Controller for Every Need The PMC™ system offers a tailored control unit for each of the various longwall functions: •• PMC™-R for roof support systems •• PMC™-D as drive control •• MC™-V for visualization and parameter setup of the P drive system •• PMC™-P node computer to act as interface between the Cat controller network, third-party systems and the mine computer. The module implements data transmission to the surface via optical fiber, modem or copper wire. •• CU for visualization and control of...

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Modularity Because PMC™ controllers are modular, each tailored control is located next to the device it is controlling. This minimizes data transfer problems and simplifies troubleshooting. Rigorous Testing All components are designed and manufactured in accordance with the latest standards and are subject to strict quality control. Circuit boards use the latest surfacemount technology and are secured in special trays to provide superior protection against shock and vibration. Rigorous quality control testing such as function control, vibration and pressure testing ensures the highest...

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PMC™-R Intelligence for Roof Supports 1 Visualization and Control Unit (VCU) at the surface 2 VCU underground 3 Data transmission underground to surface Control Unit 4 Data transmission Shield Control Unit to server PMC™-R 5 Server PMC™-R 6 Shield Control Unit (SCU) PMC™-R 7 Power supply 8 Power adapter integrated into power supply 9 Isolation adapter The PMC™-R system is the next-generation, state-ofthe-art Cat automated control for longwall roof support applications. Based on the PM4, it combines the best features of that system with additional features operators wanted. The result is an...

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Custom Keys The 30-key keypad allows a large number of additional special functions to be assigned to membrane keys, eliminating access problems for customer-specific software functions. On the standard version of the PMC™-R system information is viewed via a 2-line, LCD display which is easy to read from different angles. The information default display shows the main face data, such as leg pressure, ram cylinder stroke, shield number or shearer/ plow position. Error messages are displayed, if any occur. The LCD display can also display Cyrillic and Chinese characters. PMC™-R Roof Support...

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PMC™-D Dedicated Drive Control In combination with Cat Controlled Start Transmission (CST) drives, the PMC™-D controller offers control of AFC drives with unparalleled integration of overall system control. Typically dedicated to a gearbox or drive and mounted close to it, the PMC™-D contains all the necessary hardware and tried-and-tested CST control algorithms to control a drive system effectively. The drive control software is based on that used in other members of the PMC™ family. PMC™-D - used for measurement and control tasks Connected to a junction box in the CST gearbox, the PMC™-D...

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Controlled Start Transmission Cat CST drives with PMC™-D control unit offer high power with safe startup of the face conveyor, full utilization of installed power, long service life and compact dimensions. Cat CST drives offer: •• ntelligent compact drive for longwall conveyors I with up to 1 200 kW (1,930 hp) drive power •• aximum short-duration output torque (3 sec) of M 650 000 Nm •• lutch delivers maximum efficiency with minimum C operational slip •• Minimal energy loss and heat dissipation •• ery precise speed and torque control using V a high-dynamic clutch •• reely selectable...

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PMC™-P Brings it All Together The PMC™-P (Provider) is a node computer that provides the interface between individual controllers and equipment and the computer network or third-party systems. It converts protocols to allow data exchange. The PMC™-P also coordinates elements of the longwall. For example, if the shearer is cutting large quantities of coal, it must either speed up the conveyor drives or, if that is not possible, slow down the shearer. It also passes shearer position data to drive controllers so that they can fold in the roof support flipper at the appropriate time to prevent...

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Main View The main view shows the actual conveyor position versus the targeted position in a multi-color graph. Prop pressure values and advancing stroke values measured are presented as bar charts. Information about the shield status as well as details on position and direction of movement of the mining machine complete the main view. The three-dimensional representation of the longwall is based on the same data as the two-dimensional representation of the master control unit. The VCU and the graphic program can be linked locally or through a network. Zones of high pressure can be...

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