Controls and drives

Faceboss control system highlights:

• Production maximization through optimized cutting, high availability, automated sequences, and setup flexibility
• Advanced diagnostics using an on-board graphical display to show event logs, messages, and alarms
• Multi-lingual options, allowing the operator interface to display in a variety of languages
• Out-by communications that enable real-time machine monitoring from the surface
• Robust hardware design, created specifically for underground applications
• Standard control platform that can be used on all Joy underground mining equipment

Overview

Competitive and market pressures mean that you have to produce product at an ever-increasing rate, while always striving to decrease your cost per ton. These goals are only made more difficult by the worsening attributes of available reserves and deteriorating operating conditions.

The Faceboss control system enables your operators to operate equipment at an optimal balance of production rate and cost per ton using a powerful tool set that includes operator assistance tools, automated sequences, advanced diagnostics, machine performance monitoring, and analysis tools.

Faceboss is the standard control system platform on all Joy underground mining equipment, which ensures that you receive the same level of optimization on all your equipment. Faceboss maximizes your underground mining productivity in a variety of ways:

• Optimized cutting: cutting rate is automatically maximized during sump and shear cycles, ensuring optimal cutter loading, through the control of the traction motor speed and hydraulic shear rate
• High-availability feedback: control loops protect all electric motors from jam and thermal overloads to extend motor life and minimize machine downtime
• Automated sequences: consistent operating settings, even when changing operators or across multiple shifts, are available; for example, the one-touch shear function controls the cutter boom position to ensure the floor and roof levels are properly maintained
• Flexibility in operating parameter setups: different operating parameters for the typical cycle cutting requirements (e.g. full pass, half pass, cross cut, etc.) can be pre-defined and quickly selected via the remote station to prevent setup delays

In addition, longwall systems benefits include:

• Operator exposure: the control software is designed to minimize the operator’s exposure to dust, water spray, and noise by keeping personnel on the upwind side of the machine
• Data exchange: the control system includes integration and data exchange between the shearer and the roof support systems to maximize automation of the entire system

Wide range of standard features

The Faceboss interface also features the following:

• Advanced diagnostics: displays a log of events, messages, and alarms. All key machine operating parameters are continuously monitored and recorded, allowing the root cause of any machine failure to be quickly and easily determined
• User-friendly screens: uses intuitive screen design to simplify initial machine setup, as well as allow operators to adapt to changing mining conditions without the need to open an XP enclosure; in addition, operators can select preset tram functions from the remote to make on-the-fly cutter feedback adjustments or adjust the roof and floor cutting limits used with automation sequences
• Multi-lingual displays: can be easily configured to display in a variety of languages, allowing your operators, regardless of region, to easily use the control system
• Integrated service manuals: allows quick and easy access to critical service manuals; in addition, the interface includes step-by-step instructions for regular maintenance operations and help text for systematic troubleshooting

Remote out-by communications

In addition, the Faceboss control system enables outby communications. When your equipment is connected to a surface computer, Faceboss allows real-time monitoring of the machine from remote locations (Remote Machine Monitoring, or RMM). In addition, the control system continuously streams operating data to the surface computer.

Robust reporting options

Using the Joy surface reporting software (JSRP), the data is interpreted and value-added production reports are generated after each shift and emailed to pre-defined staff. This feedback allows managers to intervene, where required, to make necessary changes. Monthly production and engineering reports are also generated and communicated. 

OptiDrive integrated drive transmission highlights:

• Available on all Joy continuous miners, haulage systems, loaders, and longwall system equipment
• Optimizes speed control to significantly increase operator control of machine movement
• Designed for the arduous conditions found in underground mining applications
• Approved for use in all underground mining applications

Overview

Joy OptiDrive, an AC variable-frequency drive system, integrates software with the electronic and mechanical systems to provide the following features:

• Increased tram speed: significantly increases the tractive effort available, improving the equipment’s ability to climb gradients and negotiate difficult roadway conditions
• Regenerative braking: supplements the mechanical brakes, allowing them to run cooler with extended wear life; regenerative braking is highly effective at automatically maintaining constant speeds when descending gradients
• Better speed control: provides infinitely variable tram speed capability, allowing precise control of the equipment’s speed; smooth acceleration and deceleration leads to less operator fatigue and the ability to creep the machine forward slowly and prevent potential damage from inadvertent machine contact
• Less maintenance: no commutator brushes to inspect and replace mean AC traction motors are typically more reliable, more durable, and require less maintenance than DC traction motors

OptiDrive for AFC highlights:

• Specifically designed for armoured face conveyors (AFC)
• Increases safety through electronic overload protection of drive train
• Reduces chain travel up to 40% by ensuring chain remains fully loaded when running
• Reduces power consumption up to 20% through optimized speed and torque control
• Reduces water consumption up to 80% through elimination of TTTs or other coupling arrangements
• Can be retrofitted on any existing armored face conveyors

Overview

Joy OptiDrive for AFC, a variable speed drive (VSD) system, extends equipment life and reduces energy consumption. The VSD is integrated with the motor to achieve better speed and torque control, resulting in softer starts/stops and faster acceleration. The variable chain speeds that match production conditions allow for increased capacity, improved cutting cycles, and greater efficiency for your longwall system.

The OptiDrive VSD, designed for the arduous conditions found in underground mining, is approved for use in all underground mining applications. The system includes a high-quality flameproof motor, integrated with a high-power variable frequency drive, to give a single combined power unit. The system is seamlessly integrated with all components of the transmission to provide a complete drive system.

The OptiDrive for AFC provides the following key benefits:

• Improves safety performance through a high level of AFC chain management, requiring less frequent manual intervention
• Enables superior material process control for improved productivity
• Optimizes speed to control for significantly increased equipment life
• Reduces operating costs and improves reliability
• Simplifies operational maintenance
• Reduces energy consumption and services usage

Helps increase operator safety

The OptiDrive for AFC helps increase operator safety through:

• Instantaneous electronic overload protection, protecting the drive train and chain from extreme loads if the chain becomes stalled in operation
• Chain break detection, enabling instantaneous system shut-down
• Independent control of delivery and return drives, ensuring the slack chain is minimized during startup
• Full torque availability at zero speed, enabling a fully controlled system start from an overload condition

Intelligent production rate

The OptiDrive for AFC provides intelligent production rate controls to minimize the peaks and troughs of traditional longwall production, including:

• Constant rate of coal flow for a consistently high output
• No risk of overloading downstream conveyor systems
• Steady-state power demand for reduced stress on electrical equipment
• Integration with longwall shearer speed to control for maximum utilization of conveyors

Increased equipment life and reduced maintenance

The OptiDrive for AFC reduces wear to equipment components by ensuring that the chain is always fully loaded when the conveyor is running, reducing the chain travel by more than 40%. This means 40% less revolutions of the chain, sprockets, couplings, transmission and motor, resulting in significantly improved life expectancy and less downtime for equipment repairs and maintenance.

The system has low maintenance requirements and can operate in underground environments with a service interval of up to three years.

The OptiDrive for AFC has also been optimized for easy maintenance:

• Continual monitoring of the chain position allows OptiDrive to park the chain in a pre-determined maintenance position, allowing inspection and maintenance work to be done easily and efficiently
• Variable slow-speed running allows easy chain inspection and positioning
• Instant and controlled reverse running capability

Lower power consumption

In many cases, the OptiDrive for AFC replaces a controlled slip device which normally operates at 95.5% efficiency. This, in conjunction with power saving due to optimized speed and torque during non-production and reduced-production phases, can bring a power savings of over 20% when compared to a fixed-speed, soft-start system.

Easy install and commission

Since the OptiDrive for AFC is an integrated drive and motor system, it not only saves installation space but also internally manages the motor cable, eliminating the electrical protection issues normally associated with free-standing variable speed drives. Integration also means that the setup parameters are pre-set in the system during the manufacturing process. Compared to free-standing drives, the OptiDrive requires no setup – simply plug in and begin operation.