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HOME BRANDS & PRODUCTS CAT PRODUCT LINE EQUIPMENT UNDERGROUND - LONGWALL SHEARERS EL4000 - SHEARER

EL4000 - SHEARER

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The EL4000 is designed for maximum production in high seams. It is based on the EL3000, but has a cutting drum diameter of up to 3.50 m and ranging arms that allow mining up to heights in excess of 7 meters.

SPECIFICATIONS

Typical Machine Length17.0 m

Installed Power2295.0 kW

Haulage SystemAC inverter drive

BENEFITS AND FEATURES

SHEAR PERFORMANCE

shear performance

With high-powered ranging arms and haulage units, Cat shearers cut and load up to 5000 ...

LEARN MORE
KEY IMPROVEMENTS

key improvements

Cat shearers incorporate numerous new features and benefits. These are presented in the ...

LEARN MORE
MAINFRAME MADE FOR MUSCLE...

mainframe made for muscle

The unique mainframe of the Cat shearer is one of its key features. The fabricated ...

LEARN MORE

specifications

Typical Machine Length17.0 m

Installed Power2295.0 kW

Haulage SystemAC inverter drive

Applicable Minimum Pan Width1342.0 mm

Available Cutting Power2 × 750 kW; 2 × 860 kW

Available Haulage Motors2 × 150 kW (2 × 240 hp)

Body Height1070.0 mm

Coal Sizer200.0 kW

Cutting Drum DiameterUp to 3.50 m (Up to 138 in)

Haulage PullUp to 1075 kN (Up to 120 tons)

Haulage SpeedUp to 31.1 m/min (Up to 102.03 ft/min)

Height Range4.00-7.00 m (158-276 in)

Machine WeightApprox. 130 tonnes (Approx. 143 tons)

Operating Voltages3,300V; 4,160V

Pump Motor75.0 kW

optional machine mounted coalsizer cs200

TypeTransmission rating of 200 kW @ 50 Hz (320 hp @ 60 Hz)

TypeQuillshaft transmission protection

TypeDrum speed of 200 rpm (240 @ 60 Hz)

TypeAvailable motor rating 200 kW @ 50 Hz (320 hp @ 60 Hz)

TypeIntegral water cooling for transmission and motor

TypeSquare drum hub drive for drum

TypeComplete with anti-shock lift mechanism (unique to Caterpillar)

TypeDrum diameter 900 mm (35.5 in) over picks

health monitoring

TypeThis system monitors oil levels and temperatures, flows, pressures and vibration.

TypeA comprehensive health monitoring system is available.

hydraulically activated top guards

TypeThis shearer can be equipped with hydraulically activated top guards

machine @ 50 hz

Available Cutting Power2 x 860 kW (2 x 1,153 hp); 2 x 750 kW (2 x 1,006 hp)

Body Height1070.0 mm

Coal Sizer200.0 kW

Cutting Drum DiameterUp to 3500 mm (Up to 138 in)

Cutting Drum Speed30.8, 35 and 43 rpm

Haulage Motor2 x 150 kW (2 x 201 hp)

Haulage PullUp to 1075 kN (110 tons)

Haulage SpeedUp to 31.1 m/min (102.03 ft/min)

Haulage SystemAC inverter drive

Installed PowerUp to 2295 kW (Up to 3,078 hp)

Machine Weight (approximate)130.0 tonnes

Minimum Pan Width1342.0 mm

Operating Voltage3300.0 volts

Pump Motor75.0 kW

Seam Range4.0-7.0 m (158-276 in)

Typical Machine Length (drum centers)17008.0 mm

water material

TypeAll hose assemblies are to ISO 6805 and proof tested to EN ISO 1402.

TypeThis shearer is available with onboard filtration, dust suppression spray bars, shearer clearers and ranging arm spray rings.

TypeAll hose and hosing is in compliance with guideline MDG 41 and MSHA regulations.

TypeThe hoses are assembled to Hose Assembly Standard DIN20066:201-10.

haulage transformer box htb3

TypeModule contains drive system circuit breaker

two 200 kw 268 hp 600v ac inverter drives with regenerative braking module

Haulage Transformer Box - HTB3Type

this flameproof module contains the main 350 kva haulage transformer power supplies and auxiliary transformer

Mainframe - MF4Type

high structural integrity and absorption of all cutting and haulage forces providing maximum protection for all major units

Mainframe - MF4Type

maximum protection of electrical boxes providing the highest level of flameproof integrity

Mainframe - MF4Type

split mainframe in case of transportation limitations

Mainframe - MF4Type

versatility of application due to fully modular construction

Mainframe - MF4Type

improved access for maintenance and ease of overhaul and repair

Machine Automation and CommunicationLevels of Automation

statebased shearer automation “navigator 2”

Machine Automation and CommunicationLevels of Automation

zonebased automation “navigator 1”

Machine Automation and CommunicationLevels of Automation

“longwall navigator” for improved face alignment and horizon control

Machine Automation and CommunicationLevels of Automation

integrated longwall automation with “navigator 2 + 3”

Machine Automation and CommunicationType

pmc evos control system allows the shearer to be operated even if the overall control system is not functioning

Machine Automation and CommunicationType

the shearer is equipped with a stateoftheart industry pc in a flameproof housing with plenty of computing power

Machine Automation and CommunicationType

stateoftheart industry pc allows flexibility to upgrade to future features such as condition monitoring

Machine Automation and CommunicationType

unlike competitor systems modularity of the longwall system

control allows the longwall to operate in “fault-tolerant” mode.Machine Automation and Communication

type

In other words, integrated automation does not prevent control via individual PLC’s in order to keep production up and running.Machine Automation and Communication

PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality.Machine Automation and Communication

This shearer has a state-of-the-art distributed automation system for the control, monitoring and protection of the shearer.Machine Automation and Communication

A Programmable Logic Controller (PLC) takes care of basic machine control tasks, ensuring that coal is produced.Machine Automation and Communication

Industry-leading Automation from the Pioneer of State-based Automation.Machine Automation and Communication

Its modular design allows it to be configured to meet individual control needs.Ranging Arms - RA860

Transmission rating of 860 kW @ 30.8 rpm and aboveRanging Arms - RA860

Maximum drum diameter of 3500 mm (138 in)Ranging Arms - RA860

Choice of drum speedsRanging Arms - RA860

Complete with 32 mm (1.3 in) bore, through shaft PFF/PBF wet cuttingRanging Arms - RA860

Available cutter motors - 750 kW and 860 kW @ 50 Hz (1,200 hp and 1,380 hp @ 60 Hz)Ranging Arms - RA860

Maximum oil capacity of 45 L (11.88 gal) in high speed compartment and 60 L (15.85 gal) in the epicyclicRanging Arms - RA860

Integral monitoring transducersRanging Arms - RA860

Quillshaft transmission protectionRanging Arms - RA860

Square drum hub (630 mm [24.8 in] across flats)Downdrive - DD150

Innovative and unique downdrive designDowndrive - DD150

Transmission rating of 150 kW (201 hp)Downdrive - DD150

Maximum haulage pull 1075 kN (123 tons)Downdrive - DD150

Suitable for all current rack type systemsDowndrive - DD150

Removable modular top drive wheel assembly (cartridge)Downdrive - DD150

Downdrive ratio 22T - 27T - 31T - 11T (three wheel configuration)Downdrive - DD150

Trapping shoe with replaceable wear inserts, safe and easy to replace (unique to Caterpillar)Downdrive - DD150

Fully removable, rehandable, modular gearboxPowerpack - PP3

Fixed displacement pump, with a capacity of 200 L/min (53 gal/min)Powerpack - PP3

Operating system pressure of 210 bar (3,046 psi)Powerpack - PP3

Robust hydraulic reservoir of 300 L (79 gal) capacityPowerpack - PP3

This unit has a pump motor rating of 75 kW @ 50 Hz (120 hp @ 60 Hz)Powerpack - PP3

For use with ISO 68 or ISO 100 hydraulic oilsPowerpack - PP3

Available with 6 or 8 section valve bank (dependent on function requirement)Powerpack - PP3

Available with two speed ranging arm facilityPowerpack - PP3

Integral monitoring transducersElectrical Material

This model of shearer is available with headlights, cameras, methane monitoring, end displays and audible alarms.Electrical Material

All electrical material is designed and certified to IEC standards and also complies with other regional and national standards.Dimensions (Approximate)

afc pan width

1342.0 mmDimensions (Approximate)

clearance from drum to afc toeplate

380.0 mmDimensions (Approximate)

cutting drum overall width

1100.0 mmDimensions (Approximate)

diameter of shearer cutting drum

3200.0 mmDimensions (Approximate)

distance between drums with arms horizontal

17008.0 mmDimensions (Approximate)

distance between ranging arm hinge points

9600.0 mmDimensions (Approximate)

distance between trapping shoe centers

6910.0 mmDimensions (Approximate)

height to top of machine main body

2656.0 mmDimensions (Approximate)

machine height over main body

3366.0 mmDimensions (Approximate)

maximum cutting height for seam

7188.0 mmDimensions (Approximate)

ranging arm cutting drum diameter

3200.0 mmDimensions (Approximate)

ranging arm length hinge to drum

3893.0 mmDimensions (Approximate)

shearer drum undercut of floor

621.0 mmDimensions (Approximate)

top guard height over main body

620.0 mmDimensions (Approximate)

vertical tunnel clearance

1277.0 mmElectrical Control Box - ECB3

type

This flameproof module contains the majority of the shearer electrical control and power distribution components.Electrical Control Box - ECB3

High current carrying capacity of 500 amps and can accommodate trailing cables up to 240 mm2 (9.45 in2).Electrical Control Box - ECB3

All internal chassis can be ‘bench built,’ tested and stored.Electrical Control Box - ECB3

This unit also contains HV fuses, earth leakage and both visible disconnects.Electrical Control Box - ECB3

An extremely powerful PMC Evo-S control system with state-of-the-art Ethernet communication and backup functionality.Electrical Control Box - ECB3

This unit contains cutter motor contactors, circuit breakers, control transformer and current monitoring.Electrical Control Box - ECB3

Box contains various LV circuit breakers which can be reset through the FLP cover, reducing downtime.Hydraulic Material

All hose and hosing is in compliance with guideline MDG 41 and MSHA regulations.Hydraulic Material

The hoses are assembled to Hose Assembly Standard DIN20066:201-10.Hydraulic Material

All hose assemblies are to ISO 6805 and proof tested to EN ISO 1402.Haulage Units - HU150

maximum machine speed

30.11 m/minHaulage Units - HU150

pull at maximum speed

537.97 kN/120,940 lbf (55.07 tonnes/60.70 tons)Haulage Units - HU150

speed at maximum pull

15.06 m/minHaulage Units - HU150

total machine pull

1075.94 kN/241,881 lbf (110.15 tonnes/121.42 tons)Haulage Units - HU150

type

Available with Machine Parking BrakeHaulage Units - HU150

Maximum oil capacity of 25 L (7 gal)Haulage Units - HU150

Integral monitoring transducersHaulage Units - HU150

Quillshaft transmission protectionHaulage Units - HU150

Available with Machine Position EncoderHaulage Units - HU150

This unit has a haulage motor rating of 150 kW (201 hp)Haulage Units - HU150

Integral water cooling @ 9 L/min (2 gal/min)Haulage Units - HU150

Maximum power rating 150 kW (201 hp)Haulage Units - HU150

Transmission reduction of 137:1Machine @ 60 Hz

available cutting power

2 x 1029 kW (2 x 1,380 hp); 2 x 895 kW (2 x 1,200 hp)Machine @ 60 Hz

body height

1070.0 mmMachine @ 60 Hz

coal sizer

239.0 kWMachine @ 60 Hz

cutting drum diameter

Up to 3500 mm (Up to 138 in)Machine @ 60 Hz

cutting drum speed

37, 42 and 51.6 rpmMachine @ 60 Hz

haulage motor

2 x 179 kW (2 x 240 hp)Machine @ 60 Hz

haulage pull

Up to 1177 kN (120 tons)Machine @ 60 Hz

haulage speed

Up to 30.1 m/min (98.7 ft/min)Machine @ 60 Hz

haulage system

AC inverter driveMachine @ 60 Hz

installed power

Up to 2744 kW (Up to 3,680 hp)Machine @ 60 Hz

machine weight approximate

145.0 tonnesMachine @ 60 Hz

minimum pan width

1342.0 mmMachine @ 60 Hz

operating voltage

4160.0 voltsMachine @ 60 Hz

pump motor

89.0 kWMachine @ 60 Hz

seam range

4.0-7.0 m (158-276 in)Machine @ 60 Hz

typical machine length drum centers

17008.0 mm

BENEFITS AND FEATURES

SHEAR PERFORMANCE

SHEAR PERFORMANCE

With high-powered ranging arms and haulage units, Cat shearers cut and load up to 5000 ...

LEARN MORE
KEY IMPROVEMENTS

KEY IMPROVEMENTS

Cat shearers incorporate numerous new features and benefits. These are presented in the ...

LEARN MORE
MAINFRAME MADE FOR MUSCLE...

MAINFRAME MADE FOR MUSCLE...

The unique mainframe of the Cat shearer is one of its key features. The fabricated ...

LEARN MORE
INNOVATIVE TRAPPING SHOE

INNOVATIVE TRAPPING SHOE

Trapping shoes attach the shearer to the haulage rack system, part of the armored face ...

LEARN MORE
EXTENDED SERVICE LIFE

EXTENDED SERVICE LIFE

The inserts have the same wear area as conventional shoes and are articulated.

LEARN MORE
DOWNDRIVE

DOWNDRIVE

An innovative downdrive design results in longer bearing life, increased gear rating and ...

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MODULAR HAULAGE SYSTEM

MODULAR HAULAGE SYSTEM

Caterpillar has further developed its modular haulage concept with increased power ...

LEARN MORE
COALSIZER

COALSIZER

Cat shearers can be supplied with an optional rugged coalsizer, currently with up to 200 ...

LEARN MORE
PACKING MORE POWER

PACKING MORE POWER

The power pack has been reengineered to provide increased functionality, optimized ...

LEARN MORE
TESTED FOR RELIABILITY

TESTED FOR RELIABILITY

Downtime is extremely expensive for operators - costs continue to add up while nothing is ...

LEARN MORE
LUBRICATION VERIFICATION

LUBRICATION VERIFICATION

Ranging arms and haulage units are subjected to an intense test regime to establish the ...

LEARN MORE
ENDURANCE BLOCK LOAD TESTING

ENDURANCE BLOCK LOAD TESTING

This test applies loads far in excess of those encountered during normal mining ...

LEARN MORE
PRODUCTION LOAD TESTING

PRODUCTION LOAD TESTING

After successful endurance block load testing, the same test rigs are used to carry out ...

LEARN MORE
PROVEN PRODUCTIVITY

PROVEN PRODUCTIVITY

This extensive range of tests ensures the highest possible availability of shearers in ...

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INDUSTRY-LEADING AUTOMATION FROM THE PIONEER OF STATE-BASED AUTOMATION

INDUSTRY-LEADING AUTOMATION ...

Caterpillar has developed a state-of-the-art distributed automation system for the ...

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POWER AND FLEXIBILITY

POWER AND FLEXIBILITY

With extensive computer power installed and simple upgrade to new features, Cat shearer ...

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THE NET IS THE CONTROL

THE NET IS THE CONTROL

The shearer control system uses a state-of-the-art Ethernet bus, resulting in a drastic ...

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INTRINSIC SAFETY

INTRINSIC SAFETY

More components designed to be intrinsically safe means simpler installation and speedier ...

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VISUALIZATION

VISUALIZATION

Visualization not only provides a graphical representation of current operating ...

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VIBRAGUARD™

VIBRAGUARD™

VibraGuard™ allows trained personnel to predict machine component wear, avoid unplanned ...

LEARN MORE
MODULAR CONTROL OFFERS FLEXIBILITY AND POWER

MODULAR CONTROL OFFERS ...

PMC™ Evo-S brings state-of-the art processor performance underground. Designed by the ...

LEARN MORE

EL4000 STANDARD EQUIPMENT

  • trapping shoe ix
  • central lubrication system
  • pmc™ evos
  • gate end data connection
    Powerline
    WLAN

EL4000 OPTIONS

    • multipiece mainframe
    • cowl
    • spall guards
    • coal sizer
      100 kW
      200 kW
    • trapping shoe ix insert exchange
    • shearer clearer
    • spray bars
    • gate end data connection
      Fiber optics
    • ipc
    • zonebased automation“navigator 1”
    • statebased shearer automation “navigator 2”
    • integrated longwall automation with “navigator 2 + 3” only with cat longwall equipment
    • “longwall navigator” for improved face alignment and horizon control incorporates lasc technology only with cat longwall equipment
    • vibraguard™
    • cameras
    • condition monitoring
Back

MOTEUR

With high-powered ranging arms and haulage units, Cat shearers cut and load up to 5000 tonnes (5,500 tons) per hour and more, depending on mining conditions. The unique, one-piece mainframe design offers maximum structural integrity and service life.

BENEFITS AND FEATURES

The mainframe is available as a split unit in the event of transportation limitations. Featuring the superior Jumbotrack shearer haulage system, the shearer also offers advanced integrated automation and communication options.

Shear Performance

Cat shearers incorporate numerous new features and benefits. These are presented in the following pages by category.

BENEFITS AND FEATURES

The key improvements include:

  • Extremely powerful PMC™ Evo-S control system with state-of-the-art Ethernet communication
  • Improved innovative downdrive design
  • Ranging arm with longer service life
  • Further development of the modular haulage and electrical control box
  • Enhanced power pack with easy access
  • Online vibration monitoring with VibraGuard™
  • Clear wiring and use of plug and play for easy maintenance
  • Trapping Shoe Ix (Insert Exchange) for longer service life, safe and easy to replace
  • Future-proof design allowing upgrades - such as stronger ranging arms and haulage units or addition of coal sizer - during rebuild
  • Mainframe designed to handle 1200 kW (1,930 hp) ranging arms and 200 kW (320 hp) haulage units - EL3000 only
Key Improvements

The unique mainframe of the Cat shearer is one of its key features. The fabricated structure of the mainframe with cast ranging-arm hinge points results in an extremely robust design not only to meet the toughest mining conditions and ensure reliability and long service life, but also to handle even higher cutting and haulage forces in the future. The mainframe of the EL3000 is designed to allow retrofit of 1200 kW (1,930 hp) ranging arms and 200 kW (320 hp) haulage units. A split mainframe is available in case of transportation limitations.

BENEFITS AND FEATURES

Benefits

  • High structural integrity and absorption of all cutting and haulage forces, providing maximum protection for all major units
  • Maximum protection of electrical boxes, providing the highest level of flameproof integrity
  • Improved access for maintenance and ease of overhaul and repair
  • Versatility of application due to fully modular construction
  • Flexible and cost-effective equipment management
  • Independent unit exchange and selective overhaul
  • Long service life
  • Low operational costs
  • High reliability
Mainframe Made for Muscle...

Trapping shoes attach the shearer to the haulage rack system, part of the armored face conveyor, allowing the shearer to be hauled up and down the face.

BENEFITS AND FEATURES

A new type of trapping shoe­ developed by Caterpillar - the Trapping Shoe Ix - offers numerous advantages over the conventional design:

  • Greater safety and ease of handling during replacement
  • Faster replacement
  • Greater flexibility
  • Longer service life
  • Lower operating costs
The patent-pending Trapping Shoe Ix continues the Caterpillar principle of designing products with separate structural and wear parts to allow quick and easy replacement of surfaces subject to wear. The new design cuts the weight that has to be handled during replacement from more than 500 kg to less than 50 kg per insert, and cuts the time required for exchange to a fraction of the previous time. Because the weight handled is so much lower, changeout can take place anywhere along the face - previously this work had to be done at the gate ends, where heavy lifting equipment was available.
Innovative Trapping Shoe

The inserts have the same wear area as conventional shoes and are articulated.

BENEFITS AND FEATURES

This - combined with the fact that the shoe does not have to exert as much pressure, resulting in a lower point load - means less wear. Field tests of the Trapping Shoe Ix showed its service life to be 50 percent longer than conventional trapping shoes.

Extended Service Life

An innovative downdrive design results in longer bearing life, increased gear rating and greater modularity for simplified maintenance. Height adjustment of the shearer is relatively easy and is achieved with replacement of the downdrive to allow adaption to changing seam conditions.

BENEFITS AND FEATURES

Every mainframe is designed to take the full range of downdrive arrangements to fit a wide range of seam heights.

  • Fully modular design
  • Easy maintenance access
  • Fully articulating shoe
  • High pull and maximum life
Downdrive

Caterpillar has further developed its modular haulage concept with increased power rating, gear rating, bearing life and redundancy, leading to longer overhaul intervals based on typical usage. The haulage system is a simple design capable of achieving cutting speeds of up to 32 m/min (105 ft/min), with improved reliability and longer service life.

BENEFITS AND FEATURES

The fully modular haulage gearbox is located in the shearer mainframe and does not form part of the shearer structure. The haulage system offers:

  • Simple construction, improved reliability and longer service life
  • Fully proven load-sharing system
  • Reduced cost
Modular Haulage System

Cat shearers can be supplied with an optional rugged coalsizer, currently with up to 200 kW (320 hp) of installed power for maximum productivity in high seams or difficult mining conditions.

BENEFITS AND FEATURES

The coalsizer can be ordered separately for installation during rebuild or overhaul.

Coalsizer

The power pack has been reengineered to provide increased functionality, optimized performance and better access to filtration units via simplified layout. Both of the following units are modular, with drawer units providing easy access and upgrade.

BENEFITS AND FEATURES

Features Transformer Box

  • Features closed-loop control with measurement of speed, not power
  • Transforms to 600 V for haulage units’ frequency converter motors
  • Connectorized cables for reduced wiring and quick, clear installation
  • Temperature monitoring and water cooling

Control Box

  • Plug and play
  • Easy to maintain
  • Quick and easy troubleshooting
Packing More Power

Downtime is extremely expensive for operators - costs continue to add up while nothing is produced. This is why Caterpillar ensures that our superbly engineered shearers are up to the job.

BENEFITS AND FEATURES

That’s why each shearer design - which is optimized for maximum availability - is subjected to rigorous in-house testing to ensure that there are no unpleasant surprises when units are in service. Shearer production quality assurance falls into three main categories: lubrication verification, endurance block load testing and production load testing.

Tested for Reliability

Ranging arms and haulage units are subjected to an intense test regime to establish the optimum oil-level requirements to suit all mining conditions. The units are mounted on purpose-designed test rigs that are positioned to simulate the gradient of the underground seam.

BENEFITS AND FEATURES

A suite of tests is performed with a range of different gradients and arm positions to represent even the most severe mining conditions. The units are operated until stable temperatures are achieved at all gradients. This establishes the minimum, maximum and optimum oil quantities for all conditions.

Lubrication Verification

This test applies loads far in excess of those encountered during normal mining operations, ensuring that the shearer can operate reliably at the installed power ratings. Ranging arms or haulage units are mounted on purpose-designed test rigs in a back-to-back configuration driven by a suitable test motor.

BENEFITS AND FEATURES

The endurance block load test imposes loads from 100% to 175% to ensure that the ranging arm design meets the requirements of the most demanding applications. Input torque, losses and output torque are monitored during the test, as are bearing, gear and shaft temperatures. Vibration is monitored by dedicated sensors. Oil samples are collected at intervals for analysis, as the presence of metal in the oil can indicate excessive component wear. On completion of the endurance test, units are dismantled for a full internal and external inspection to verify that the design is fit for purpose.

Endurance Block Load Testing

After successful endurance block load testing, the same test rigs are used to carry out production load testing of all ranging arms and haulage units.

BENEFITS AND FEATURES

The test gradually increases the load up to full load. All temperatures and vibration points are monitored during the test, and oil samples are again collected for analysis.

Production Load Testing

This extensive range of tests ensures the highest possible availability of shearers in service and maximum return on investment for your longwall installation.

BENEFITS AND FEATURES

Nothing is left to chance in ensuring that our shearers are unsurpassed in reliability.

Proven Productivity

Caterpillar has developed a state-of-the-art distributed automation system for the control, monitoring and protection of the shearer. Its modular design allows it to be configured to meet individual control needs, from basic monitoring and protection to advanced automation and data transmission.

BENEFITS AND FEATURES

The PMC™ Evo-S control system with state-of-the-art Ethernet communication and backup functionality allows the shearer to be operated even if the overall control system is not functioning. In 2002, State-Based Automation was invented and launched. Using this technology, Caterpillar now offers a comprehensive range of automation products.

Industry-leading Automation from the Pioneer of State-based Automation

With extensive computer power installed and simple upgrade to new features, Cat shearer automation is fit for the future. Components connect into the network rather than directly to a central computer, simplifying installation, wiring, maintenance and troubleshooting.

BENEFITS AND FEATURES

The shearer is equipped with a state-of-the-art industry PC in a flame-proof housing with plenty of computing power, allowing flexibility to upgrade to future features such as condition monitoring. A Programmable Logic Controller (PLC) takes care of basic machine control tasks, ensuring that coal is mined. Unlike competitor systems, the modularity of the longwall system and control allow the longwall to operate in “fault-tolerant” mode, even when there is a problem with the overall automation system. In other words, integrated automation does not prevent control via individual PLCs in order to keep production up and running.

Power and Flexibility

The shearer control system uses a state-of-the-art Ethernet bus, resulting in a drastic reduction in wiring and a huge increase in flexibility. There are no interfacing problems, as equipment connected to the network only needs to be able to communicate via Internet Protocol.

BENEFITS AND FEATURES

Commissioning, maintenance, upgrades and troubleshooting are much easier and faster, and equipment is self-configuring. The few cables that are used are standard Ethernet cables rather than application-specific cables - cutting costs and simplifying spare parts inventories. Flameproof housings are no longer required, simplifying installation and speeding up maintenance. New modules are based on standardized CIOS™ modules (configurable input output system), resulting in a plug and play approach to upgrades. No reprogramming is necessary. Remote control and diagnosis are also possible for all components. And because of the Ethernet-based approach, the failure of one component does not impact the whole system.

The Net is the Control

More components designed to be intrinsically safe means simpler installation and speedier maintenance. New modules are based on standardized CIOS™ modules, resulting in a plug and play approach to upgrades.

BENEFITS AND FEATURES

Changes to the system only require commissioning changes - such as mounting and connection of sensors. No replacement of control software is required. Remote control and diagnosis are also possible for all components. And because of the Ethernet-based approach, the failure of one component does not impact the whole system. This not only supports the unique “fault-tolerant” mode, which allows the longwall to continue to operate when there is a problem with the overall automation system, but also, through systematic isolation, allows faulty units to be identified while production continues.

Intrinsic Safety

Visualization not only provides a graphical representation of current operating conditions, but can also display historical conditions and a graphic display of trends. An automated longwall is a highly complex system with many interacting components generating time-variant data.

BENEFITS AND FEATURES

Visualization gives operators a better understanding of the overall system, allowing them to further optimize operations. VLongwall provides a system overview and access to the dedicated visualization modules VShield, VDrive, VPlow and VShearer. It also gives access to VTrend for trend analysis and VGraph3D for waterfall plots of the entire longwall.

Visualization

VibraGuard™ allows trained personnel to predict machine component wear, avoid unplanned downtime and set alarms to warn the operator if monitored machine components run the risk of damage. This comprehensive protection backs long life and high availability of your valuable mining equipment.

BENEFITS AND FEATURES

Benefits

  • Permanent online monitoring and protection of equipment instead of sporadic offline measurements
  • Assists in the prediction of machine component wear
  • Alarms warn the operator if monitored components are at risk of damage
  • When utilized by trained personnel, VibraGuard™ makes repairs predictable and helps avoid unplanned downtime
  • Repair work can be done largely without stress
  • Allows timely procurement of spare parts
  • Transfers data to a surface control center PC for detailed analysis and evaluation
VibraGuard™

PMC™ Evo-S brings state-of-the art processor performance underground. Designed by the market leader in shearer automation, the advanced Cat automation package allows improved utilization of manpower in a safe environment; with increased yield from any given seam section, faster haulage speeds, improved face management and increased life of all longwall equipment, including AFC and shields.

BENEFITS AND FEATURES

Automation systems match your needs - from basic to highly sophisticated - while remaining easy to install, operate and maintain. The modular control concept is:

  • Easily expandable based on modular design
  • Ready for integration of highly sophisticated technologies and devices
  • Equipped for XML-based interfaces to third- or fourth-party systems

Making it Easy

  • Cat self-configuring controls and standard interfaces such as Ethernet allow quick and easy system configuration changes with no programming effort
  • Ready for future technologies such as high-quality condition monitoring, including vibration monitoring
  • Easy and flexible adaptation to existing data environments
  • Greater use of Ethernet, standard connectorization and PMC™ control family mean greater simplicity, reduced spares inventories and shorter downtimes
  • Standardization and modularization allow quick and easy customization of components and systems

Fast Troubleshooting

  • Widespread use of intrinsically safe components allows large-scale fault diagnosis under power
  • Remote access to most components down to I/O level
  • Diagnosis from surface or by Cat Mine Control Center
  • Managed switches and field bus coupler (FBC) allows selective routing:
- Permits sequential disable and enable of components and/or communication routes - Isolation of faulty units until next repair shift allowing production to continue

Less Maintenance Effort

  • Widespread use of intrinsically safe components in PMC™ Evo-S reduces time-consuming opening of flame-proof housings in the event of faults.
  • Quick and easy exchange of modules.

Modularity is Strength Modularity is a key feature of the Cat shearer. It results in independent major units, each driven by its own dedicated electric motor and housed within or attached to a robust mainframe unique to the Cat range. Control systems are also modular. This modular design offers maximum availability - through “fault-tolerant” mode operation - and the flexibility to meet even the most demanding customer requirements by upgrading components such as the ranging arm.

Modular Control Offers Flexibility and Power