MECHANISED COAL
Matrix’ s IntelliZone technology reduces nuisance warnings and shutdowns. Awareness Zone around the continuous miner( CM) tail automatically shrinks in cutting mode. Awareness Zone on the CM expands when disengaged from shuttle car and contracts when engaged
more than 2,000 kW. KAMAT pumps are optimally suited for hydraulic pressures of 350 to 420 bar in mining: its high-pressure pumps were developed for 3,500 bar in continuous operation.
Armoured Face Conveyors
At Longwall USA in 2015, Gareth Rimmington, Principal Engineer, Joy Global, noted in Variable Speed Drives on Armoured Face Conveyors the dramatic advances in AFC drive systems.“ From fixed-fill fluid couplings, through variable-fill TTT water couplings, to medium voltage( 4,160 V and 3,300 V) variable speed motors, AFC drives continue to be one of the most developed components of a longwall system.
“ The introduction of variable speed drives( VSDs) has created huge opportunities to increase longwall productivity and efficiency, but realising the full potential of VSDs requires the simultaneous evolution of longwall control and automation systems.”
Continuous miners / roadheaders
Simulation Based Continuous Miner Production Training at Longwall USA, by Joey Kennedy, Senior Training Instructor / K9 Handler – Alpha Natural Resources, examined advances in simulation based operator training. This has assisted greater productivity through better instruction and assessment of operational techniques.
Recognising that traditional training in an“ apprenticeship format” is not ideal and the difficulties of instructor-based training in the underground environment, the solution is to use“ a combination of instructor led and simulation based training.”
“ A seasoned continuous miner trainer was first sent to a targeted operation, to observe mining conditions and current operational technique. Particular attention was paid to shearing methods( i. e. cut cycle); to the extent that the operator trainer experimented with different cut cycle methodologies to determine the optimal approach for a given operation. The operator trainer then replicated the conditions in an operator training simulator, to objectively assess the productivity of operators versus the proposed change by the operator trainer. The trainer then used the 3D visualisation and playback tools available within the simulation together with instructor-led training to coach operators on the new cut cycle. Finally, real world performance was tracked before and afterwards to measure the rate of improvement from the new cut cycle.
“ The results from this new approach to operator training have been improved production rates at the target operations by 5-10 %.”
In January 2015, the Mine Safety and Health Administration( MSHA) issued a federal rule requiring all continuous miner systems to use proximity detection systems. These systems help train personnel to avoid danger zones while working around large machines, such as continuous miners and mobile haulage equipment. They detect workers in low visibility and obscured operator line-of-sight locations and can be used on a wide variety of equipment.
The Joy SmartZone proximity system helps teach personnel to operate underground mining equipment from safe working zones, as well as to stay away from danger zones. SmartZone recognises and monitors individual personnel movement around a machine, providing an additional layer of analysis for in-depth training initiatives.
The SmartZone system is made of two related components: n Drivers are placed strategically on the equipment, covering a variety of directions and angles; the drivers then work together in a coordinated fashion to track the position of any person wearing a Personnel Wearable Device( PWD) n PWDs are compact devices, roughly the size of a cell phone, worn by mining personnel; each PWD emits a signature signal that is recorded and tracked by the drivers. SmartZone maintains two distinct operating zones around equipment: n Initial Warning zone where SmartZone audibly and visually signals the person, through their PWD, that he or she is getting too close to the equipment n In the Shutdown zone, SmartZone disables various machine functions when it detects a person with a PWD in that zone.
While the shape of the zones is dependent on the shape of the equipment, both the initial warning zone and shutdown zone will be the same shape. The only difference between them will be their size.
In addition, when SmartZone is installed on multiple machines, the drivers interact seamlessly between the machines, detecting if a person with a PWD is in zone one or two for any or multiple machines.
Similarly, the Matrix IntelliZone ® proximity detection system also embraces a Warning Zone( shown in yellow) that uses highly-visible flashing lights to warn workers they are close to potential danger, and may reduce the speed of a vehicle or influence other changes in operation. The Shutdown Zone( shown in red) is closest to the equipment and causes immediately shutdown, and other actions, when a worker or IntelliZone equipped machinery enters this area. Additional zones can be configured if needed. IntelliZone Awareness Zones can have any shape and are customisable to specific equipment and applications.
Mobile haulage( or light vehicle) awareness zones can be configured to vary based on speed and direction of travel. At higher speeds, longer forward zones allow additional response time for dangerous situations. Mobile haulage awareness zone can‘ see’ through ventilation curtains to warn of worker collisions.
Six-head bolter behind CM
In partnership with a US customer, the engineering department of J. H. Fletcher & Co was tasked to design and manufacture a new roof bolting machine with six independent drilling apparatus onboard capable of drilling and bolting the mine roof and side walls( rib) simultaneously. The machine is also equipped with material handling.
This is the first Fletcher ® six-head machine to
SEPTEMBER 2016 | International Mining 139