As one of the mining sector’s leading OEMs, Komatsu is constantly innovating ways to improve safety and efficiency on a mine site. One solution in particular could be a game-changer underground.
In partnership with a customer, Komatsu has developed a solution designed to improve operational synergy and safety in longwall coal operations.
Introducing the AFC Faceboss RS20s control system.
Based on the existing RS20s platform for powered roof supports (PRS), the control system leverages a broad pool of engineering resources and technological smarts to improve armoured face conveyor (AFC) performance and expand the possibilities of underground coal mining.
The AFC Faceboss RS20s control system was trialled in partnership with the Springvale mine in NSW, paving the way for the world’s first fully functional turbo transmission technology (TTT) autonomous coal clearance control system to be installed at the operation.
Komatsu control and automation product manager Shane Cooling said the new system was long overdue.
“The old system’s been around for decades and some of the components were becoming obsolete and had a complexity of marshalling boxes with busy cable runs,” he told Australian Mining. “The legacy system also does not provide the same local fault analysis capabilities as the RS20s.
“It was getting to a point where the old system was running out of memory, so we decided it was time to integrate into our other proven systems, intrinsically safe (IS) RS20s control system.
“This platform allows operators to view data directly from the mimic and HMI (human–machine interface), which helps keep operators away from moving parts and improves safety.”
Integrating the AFC Faceboss RS20s control system into the existing PRS platform means customers maintain less equipment while operating a control system that is familiar to them.
The AFC Faceboss RS20s control system provides customers with a Komatsu Joy operating platform with synergy across all products. It also standardises use of parts across AFC and PRS control platforms.
The AFC control and monitoring features are concentrated into a single control platform, improving integration, customer interaction and scheduling. The AFC Faceboss mimic controller has a specially designed facia plate based on a similar button layout and construction to the PRS mimic.
Built around AFC functions, the mimic controller can also be viewed from multiple locations, allowing greater control and monitoring.
Customers are looking for greater interaction and fault diagnostics in control systems.
The AFC Faceboss RS20s control system’s fault-finding is more intuitive, with alarms and warnings advising operators of problems and where they exist. It can also override and provide fault tolerance for I/O (input/output) to maintain production until maintenance is planned.
This provides customers more control when managing software updates, making the system easier to maintain and improving software delivery times.
Greater operational autonomy leads to improved safety outcomes.
“Operators could be at any mimic across the coal clearance system and easily monitor the machine sensors without having to go back and forth,” Cooling said.
The AFC RS20s control system is favourable for maintenance, enabling fixes to occur quickly and efficiently.
“This includes changing and setting parameters from the mimic, setting overrides, and operating the PAT (pivoting arm tensioner) control,” Cooling said.
“Features like this improve efficiency, are convenient for the operator and remove them from high-pressure hydraulics exposure, creating a safer environment.
“If the customer wanted to do maintenance on the chain, for example, they can now use the slow runner through the mimic itself, meaning they can control the chain movements from a single vantage point, which negates the need to have an operator at both ends of the face.”
With plug-and-play (P&P) technology, the system comes ready out of the box to suit site setup for AFC drive controls and automatic chain tensioning. P&P technology means components can be easily changed out without the need to change the physical wiring.
The RS20s control system is also scalable, meaning new features can be added as they get developed, such as the Faceboss RS20n high-speed network.
Komatsu’s Smart Solutions team can safely monitor the AFC control system remotely while maintaining communication with the on-site team, adding even more flexibility to longwall coal operations.
This feature appeared in the September issue of Australian Mining.