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Longwall mining equipment

Joy-engineered powered roof support (PRS) solutions

  • Support rating 1 750 metric tonnes 1,929 short tons
  • Support widths 1.5, 1.7, 2.0 m or more 4.9, 5.7, and 6.7 ft. (1.5, 1.7, 2.0 m or more)
  • Operating heights .8 - 7.8 m 2.6 - 25.6 ft.

Collaboration for seamless integration and advanced automation

For a productive longwall working environment, you want solutions from world-renown experts. With a Joy-engineered PRS solution, Komatsu partners with you from design, working with your preferred manufacturing partner, through installation/integration and operation.

  • Confidence of design with 75 years of longwall powered roof support experience 
  • Designed for individual applications, 15,000 to 90,000+ cycle longevity 
  • Productivity and safety benefits of available 100% face automation 

Features and benefits

Advanced automation for productivity, protection

Advancing the journey to zero harm and higher productivity, Joy Faceboss RS20s control system integrates into the longwall and mine-wide system for automatic control of the longwall operation — including fully automatic shearer and roof support gate turn rounds.

Technical expertise

For confidence in the performance of your powered roof supports, we design and engineer your solution using our experience in longwall mining, as well as the latest expertise and technology.

Reliable structures

You can see a 20% longer PRS life and fewer required rebuilds for lower ownership costs due to detailed and controlled designs. *based on internal data

High performance cylinders

Fewer PRS rebuilds and higher fatigue lives lower your costs of ownership, that can result from Joy designs, including innovative leg feed locking system, elimination of transverse welds and bespoke leg seals. Single and double telescopic design options and various leg bore sizes available.

Effective hydraulics

Roof supports that can keep up with your shearer cutting for excellent productivity with fast cycle times. The Faceboss Compak distributed valve system puts valve gear next to the function it controls, supporting responsiveness and reducing hoses by up to 32% compared to standard designs.

Next-level longwall automation

You’ll be well on your way to a fully autonomous face with Komatsu’s RS20n control system, especially its 1 GB/s ethernet high-speed communications backbone.

Automated face alignment for consistency

The improved consistency and elimination of virtually all alignment shears can increase production up to 10%.* Inertia navigation system in shearer measures the straightness of the longwall and the Faceboss system uses that data to make path corrections. *based on internal testing vs. longwall without feature

Personal Proximity Detection for added safety

This system advances the journey to zero harm by preventing movement of an advancing shield if the system detects a worker in harm’s way. Full integration into the Faceboss Control System eliminates the need for additional components.

Enhanced Geometry Control

Provides an additional level of control, automation and worker care with anti-collision, cavity detection and unplanned movement systems.

Cameras for continuous monitoring

Reduce the number of operators underground and out of harm’s way by monitoring the entire longwall operation with a system of rugged cameras providing real-time video. Can complement Joy’s high-fidelity 3D visualization system.

Direct service support for uptime

When service, maintenance and parts are needed, you can get back up and running quickly working directly with Komatsu. You benefit from expedient turnaround times, high-quality repairs and rebuilds. Our service/parts centers are strategically sited close to longwall operations.

Quality assurance

Keeping your longwall and PRS system up and producing is key. All structural fabrications undergo advanced finite element analysis (FEA) computer simulations, then we work with you to provide engineering support throughout the testing process.
Support you can count on

Technology that works as hard as you do

Parts_UGSR_Solenoid_EXPO3.psd
Unlock the power of automation for the journey to zero harm and increased productivity with the global dual solenoid valve for powered roof supports. Its serial connectivity enables a distributed system for fast response. Can be used with any PRS system; common control with shearer and AFC advances Komatsu remote operation capabilities.
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More control is in your operators’ hands, as the RS20s standardizes the control system across all Komatsu longwall products. It can operate as a standalone system or integrate with powered roof supports and shearers. Commonality promotes easier parts management, maintenance and product support.

Learn more about advanced automation for productivity, protection

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The improved consistency and elimination of virtually all alignment shears can increase production up to 10%.* Inertia navigation system in shearer measures the straightness of the longwall and the Faceboss system uses that data to make path corrections.

*Based on internal testing vs. longwall without feature

Automation in underground mining
Automation is becoming a larger part of the longwall mining process; operators are moving farther from the face and its associated safety concerns. Newer technologies, including powered roof supports (PRS) automation, advanced shearer automation (ASA) and personal proximity detection systems are designed to make mines more efficient while enhancing worker safety.

This system advances the journey to zero harm by preventing movement of an advancing shield if the system detects a worker in harm’s way. Full integration into the Faceboss Control System eliminates the need for additional components.

Find what works for you