An on-line realtime monitoring and data-logging system for continuous miners developed by a local company with assistance from a software developer has helped a number of collieries to markedly increase production and reduce costs.
The companies responsible for the development of this unique system - believed to be the first in the world in this application - are leading coal mining equipment suppliers Voest-Alpine Mining & Tunnelling of Delmas and scada software company Adroit Technologies of Randburg.
The Voest-Alpine monitoring system (VAMS) is well in advance of any other CM monitoring systems available. The system, written on the Adroit scada software package, includes a mimic display, local and remote data-logging and Internet-based reporting. Twelve systems are currently in operation at 12 collieries, monitoring a total of 23 CMs.
"It has been designed as an open system that can be retrofitted to existing operating CMs. It can also be adapted for use on any electrically-supplied underground mobile or stationary mining equipment," pointed out Tommy Gibson, Voest-Alpine's Manager: Automation and co-ordinator of the project.
Noteworthy features of the VAMS software system include:
* All functions of the machine are displayed in the form of a mimic of the particular machine, as well as monitoring key areas such as methane levels and gearbox and oil temperatures.
* All alarms and selected data are logged and can be sent via SMS or e-mail to designated personnel.
* The package also has a trend report facilitating statistical analysis and operation information for management reports using Internet technology.
On the hardware, features on the power line modem include:
* Networking capability, allowing for multiple machines to be monitored in the same underground section.
* The system is modular in construction to reduce down-the-line costs and facilitate operation on non-Voest-Alpine equipment.
* It incorporates the fastest available baud rate to cater for inclusion of voice and video.
Trend graph reports are generally used to carry out statistical analysis of the machine's performance, but can be configured to reflect any aspect being data-logged.
"If for example you needed to investigate the events during a typical cutting cycle of the CM second-by-second, you could configure the trend graphs to reflect sumping distance, cutter boom height position, cutter motor current and tonnage calculation - all plotted over time. This would typically reflect the efficiency of various sump depths as well as operator performance," Gibson commented.
The 'generic' reporting module is primarily used for management reporting and is web-based for ease of use. "As long as there is network connection and the PC has Microsoft Internet Explorer operating, you can query the database through an active server page. Generally these reports are configured to be user-specific so if an end-user needs to report on his own criteria on a regular basis this would be saved as his own report."
A typical Voest-Alpine machine has 147 scanned points, in either digital or analog outputs. Data from the machine sensors are generated in the machine's computer and in response to requests this is dispatched through the controlled area network (CAN) bus to the machine interface power line modem (PLM) over the trailing cable conductors into the substation interface PLM. This is then transmitted via the leased line modems to the PC on surface, where a live mimic can be displayed.
It can be extended to the mine LAN or connected via a remote access server on a 'slow' communication link to a remote network, typically in a control room at Voest-Alpine's head office. Gibson added that while the package does have control capabilities, the system is only used at present for monitoring and evaluating machine performances.
He said that feedback from users to date indicates that significant savings have been achieved as a result of early warning of impending cutter head gearbox failures. "In addition, while it is difficult to quantify the productivity improvements resulting from on-line monitoring, the actual and potential productivity benefits are beyond dispute.
"For example, if the system is used to investigate the cutting cycle and a 30 s improvement is achieved, a 10% improvement in the cutting cycle would be achieved. The system enables users of CMs to identify and attend to problem areas. There are also many maintenance engineering benefits resulting from being able to view the machine on-line and each user has his own list of criteria that he monitors."
Voest-Alpine is initiating a pilot project to reduce the maintenance crew underground. This will require that the system be used to carry out on-line condition monitoring on surface, with maintenance personnel only having to go underground when problems occur or adjustments are required.
Voest-Alpine Mining & Tunnelling
(013) 665 1075
| Tel: | +27 11 658 8100 |
| Email: | [email protected] |
| www: | www.adroit.co.za |
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