Csna15204enc 001

ISSN 1018-5593
European Commission
technical coal research

Mining operations
Monitoring systems for roadheaders
European Commission
Mining operations

N. D. Jenkinson
British Coal Corporation
Stoke Orchard
Cheltenham
Gloucestershire GL52 4RZ
United Kingdom
Contract No 7220-AB/825
1 April 1989 to 30 September 1992
Final report
Directorate-General XVII
Energy
1997
EUR 15204 EN
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Luxembourg: Office for Official Publications of the European Communities, 1997

ISBN 92-827-8913-6
ECSC-EC-EAEC, Brussels Luxembourg, 1997
Reproduction is authorized, except for commercial purposes, provided the source is acknowledged
Printed in Luxembourg
CONTENTS
Synopsis
1.0
INTRODUCTION
2.0
PROGRAMME OF WORK
12
3.0
ANTICIPATED BENEFITS OF A ON-LINE ROADHEADER MONITORING

SYSTEM
12
4.0
ROADHEADER MONITORING SYSTEM SPECIFICATION & REQUIREMENTS
13
4.1
Requirements Specification
13
4.2
Identification of Monitored Parameters
14
4.3
Performance and Health Monitoring Functions
15
4.4
Machine Health monitoring parameters for Underground Trial
15
5.0
SYSTEM HARDWARE
16
5.1
Multipurpose Automation Control Equipment (MACE)
16
5.2
Transducers
17
5.2.1 Pressure and Temperature
17
5.2.2 Power Transducers
18
5.2.3 Pressure Switches
18
5.2.4 Filter Condition Monitoring
18
5.2.5 Boom Position
19
5.2.6 Flow Measurement
19
5.2.7
19
Oil Level
Contents Continued...
5.3 Underground to Surface Data Transmission
5.3.1 Applications Protocol for Boom Type Roadheaders
20
5.3.2 Underground to Surface Data Transmission Link
20
5.3.2.1
Machine to Gateroad Trailing Cable Data Transmission Tests
20
5.3.2.1
20
5.4 Surface Monitoring System
6.0
21
5.4.1 DEXTERITY Overview
22
5.4.2 Surface Hardware for Roadheader Monitoring Trial
23
SURFACE SOFTWARE & CONFIGURATION
23
6.1
Real-Time Machine Performance Displays
24
6.2
Historical Machine Performance Displays
25
6.3
Real-Time Machine Health Displays
25
6.3.1 Hydraulic Services
25
6.3.2 Electrical Services
26
6.3.3 Water Services
26
Historical Health Monitoring Display
26
6.4
7.0
20
UNDERGROUND TRIALS AT MIDDLETON MINE
26
7.1
Middleton Mine Site Description
26
7.2
Trials Machine
27
7.3
Site preparation and Installation of the Monitoring System
28
8.0
SYSTEM COMMISSIONING
30
9.0
SYSTEM TESTING
30
10.0
CONCLUSIONS AND RECOMMENDATIONS
31
FIGURES
1.
Illustration of the Complete Roadheader Monitoring System
2.
MACE Mounted on Roadheader
3.
Boom Position Sensors mounted on Roadheader
4.
'Intelligent' Flow Transducer and Interface Circuit
5.
Current Machine Utilisation Display
6.
Current Boom Position Display
7.
Debris Clearance System Display
8.
Historical Machine Utilisation Display
9.
Illustration of Machine Percentage Utilisation Display
10.
Actual Display of Machine Percentage Utilisation
11.
Machine % Utilisation Multiple Shift Display
12.
Transducer Thermometer Display
13.
Hydraulic Services Display
14.
Illustration of Elecrical Services Display
15.
Typical Water Circuit Display
16.
Transducer Trend Graph Display
17.
RH1/4 Roadheader at Middleton Mine
18.
Pressure Switches Mounted on Roadheader
19.
Pump Supply Monitoring Transducers
20.
Filter Condition Monitoring Sensors
21.
Water Circuit Flow and Pressure Transducer Mounted on Roadheader
22.
Power Transducer, MACE PSU and Ruggedised Modem Mounted on Roadheader
23.
Junction Boxes Mounted on Roadheader
24.
Monitoring System Cabling Details
TABLES
1.
Full List of Roadheader Parameters
2.
Machine Variables Real and Derived
APPENDICES
1.
On-Line Performance & Health Monitoring for Roadway Drivage Machines
2.
Development of an 'Intelligent' Turbine Row Transducer
3.
Application Sheet for Monitoring of Roadheaders using MACE
4.
Pilot Core Data Transmission Tests
5.
Surface Monitoring Functional Specification
SYNOPSIS
This project is concerned with the application of the TSRE developed Multi-purpose
Automation and Control Equipment (MACE) for performance and health monitoring of
roadway drivage equipment used in British Coal mines.
The report identifies the requirement of a monitoring system for drivage machines and details
the anticipated benefits to a colliery of installing the monitoring system.
The report describes the hardware associated with MACE for roadheader monitoring and
details software requirements for the surface computers. Followed by the subsequent
underground testing of the complete monitoring system at Middleton mine.
The report draws overall conclusions and recommendations, and identifies possible future
work in the area of transducer development.
LO
INTRODUCTION
The microchip revolution has started to influence mining methods over the last two decades.
In particular the area of monitoring, where data from remote sensors can be transmitted and
displayed at the surface. Areas that have benefited from this technology within British Coal
are underground environment, static plant and coal face. Monitoring of these areas has
illustrated the benefits of remote sensing of underground conditions to British Coal
management. '
Many collieries have experience with the MIDAS steering system fitted to shearers, which
offers machine guidance within the coal seam, accompanied by a comprehensive parameter
monitoring facility. The monitoring package offers the facility to retrieve data from a variety
of health transducers, specific to the MIDAS system. These include pressure, temperature,
flow, oil level and debris analysis. The steering system also incorporates dedicated sensors
to enable the system to control the machine.
Since the start of the rationalisation of British Coal, reducing costs and increasing productivity
per man shift has become of great importance. Methods of working have had to change so
that more faces are being driven in retreat To enable retreating faces to be installed and
operating in the shortest possible time gate roadways have to be driven faster and coalface
equipment installed quicker. The attention given to drivages has highlighted the shortfalls in
available information on drivage performance and machine utilisation.
Average drivage rates in British Coal are only 30% of best performances achieved. There is,
therefore, considerable potential for improvement and one approach to the problem is to
install continuous monitoring systems on roadheading machines to provide data for analysis
of the causes of low performance and poor reliability. No system currently exists which
incorporates the benefits of remote on-line monitoring in a form currently available for the
environment, static plant and the coal face. To many people the benefits of such a system are
all to clear. The aim of the project is to develop, apply and evaluate monitoring equipment
for this purpose.
Such systems will offer a comprehensive condition monitoring information system with onboard machine displays for operators and data transmission to a surface computer for
management, and for storage and analysis in a Colliery Information System. Transducers
which are capable of measuring key functions will be installed on the machines.
The expanding use of intelligent systems for monitoring and control has resulted in an
increase in both the types and numbers of sensors used on mobile plant. The data is normally
obtained by connecting each sensor directly to an appropriate input channel on a central
computer on the plant or close to it. As the numbers of sensors increase this leads to complex
wiring requirements, system inflexibility, poor reliability and potentially poor data integrity.
Data integrity becomes especially important when data is passed from one sub-system to
another for integrity control.
The Project will be based on the British Coal I.S (Intrinsically safe) computer MACE,
(Multipurpose Automation and Control Equipment) and will investigate and develop
alternative methods of data collection and instrumentation which overcome the limitations of
11
existing systems. New methods must provide interfaces for both analogue and digital
transducers and have the flexibility to add extra transducers in a simple manner. Data
integrity aspects will be examined together with the possibilities of two-way interaction with
intelligent transducers for features such as auto-calibration.
The successful application of real time monitoring to roadheading machines will allow
thorough analysis of performance and reliability and lead to improved equipment, greater
reliability, improved maintenance and greater machine utilisation, with the expectation of
increased drivage rates and productivity.
2J)
PROGRAMME OF WORK
The general plan of work was as follows:1)
Identify and specify the requirements of an on-line monitoring system to provide both
health and performance information in a format suitable for colliery personnel.
(Appendix 1)
2)
Identification & procurement system hardware, transducers, and associated mounting

equipment.
3)
Development of appropriate transducers not currently available to monitor an

identified parameter.
4)
Configuration of system hardware to suit the specification of the on-line parameters.
5)
Specification and design of surface displays and data analysis algorithms. (Appendix
2)
6)
Surface testing of the complete monitoring system, both hardware and software.
7)
Preparation of machine and trial site at Middletion Mine, Derbyshire.
8)
Assessment of results, analysis and report on the work carried out.
M
SYSTEM
The successful application of real time monitoring on roadheaders will provide a full analysis
of performance and reliability. This information can be used by the operators and management
to run machines more efficiently. In order to give optimum performance and better
maintenance scheduling, thus leading to greater machine utilisation, increased productivity and
provide enhanced drivage rates.
12
Previous tunnelling machine monitoring work has indicated that a correctly monitored
roadway drivage machine, with information available to both the underground operators and
surface colliery staff, could provide a number of benefits:
1)
The facility for the operator to be informed of malfunctions in any of the

machines services, and the ability to select operational information such as
cutting head position.
2)
The ability for maintenance staff to access service parameter information to

help with machine diagnostics and the identification of service deterioration.
3)
The facility of storing, analysing and displaying detailed information at the

surface, using the machine to surface data transmission system allowing current
machine utilisation, and all service information to be available on-line.
4)
The recording and presentation of operational and service history to enable

engineering staff to determine impending problems and take some preventative
action.
4J)
ROADHEADER
REQUIREMENTS
MONITORING
SYSTEM
SPECIFICATION
&
The reason for installing a monitoring system to any type of mining equipment is to enable
colliery personnel to have a better understanding of the work carried out, and able to act upon
the information received. Environmental monitoring systems are now used extensively
throughout British Coal, and monitoring of shearers has been available for a number of years
with the MIDAS system, and is used solely for health monitoring by a number of collieries.
The development of underground microprocessor based equipment and the large improvement
in surface computing power with respect to cost,make it possible to provide and extend the
facilities available on shearers to roadway drivage machines.
Previous work carried out on ECSC project 7220-AB/814 highlighted the lack of equipment
available for establishing a comprehensive 'on-line' monitoring system for roadheaders. It
concluded that the MACE unit with its associated equipment (ie power supply and
communication system) offered the best possible solution for a roadheader monitoring
package. With the MACE unit providing power for transducers directly it also overcomes the
need to have barriers between transducers and the data acquisition system. This was required
with previous systems, where transducers were power from separate supplies.
4.1
Requirements Specification
With the development of a new monitoring system it is important to identify the user
requirements for the system, including which colliery personnel are to benefit from
the system and what level of information each level each group is allowed to access.
The colliery manager will be generally interested in the daily performance of the
13
drivage machine, in particular the drivage rate, machine utilisation and reasons for
major stoppages. This information should be made available on in the appropriate
form via the surface computer system.
The colliery mechanical and electrical departments will require information on both
machine performance and condition monitoring functions with a view to the
management of maintenance resources and for planning and provisions for machine
stoppages. The facility for interrogation of the drivage machine's services (i.e. oil
levels, filter condition, electrical supply, hydraulic flows, pressures and temperatures)
should be made available for problem solving both at the surface and on the machine.
The machine operator and underground craftsmen will be concerned with the
interrogation of monitored parameters on the machine enabling problems in the
machines services to be identified precisely and quickly.
From the considerations regarding colliery staff a roadheader monitoring system can
be summarised as follows:a)
Drivage Performance and Machine Utilisation:

colliery management
engineering staff
b)
Health of the Drivage Machine's Services:

engineering staff
machine operators
craftsmen
4.2
Identification of Monitored Parameters
Table 1 provides an indication of the health monitoring information which could be

acquired form a drivage machine. Obviously it is impractical for any monitoring to
monitor and analyse such a vast amount of data. Firstly; The MACE unit mounted on
the machine has a limited number of inputs, and secondly the surface monitoring and
display system would soon be overloaded with the amount of data being transmitted
from below ground.
Therefore it is important that only the essential parameters and items of equipment are
monitored, such that the system provides a comprehensive but efficient monitoring
function to mine management. For this reason a document detailing the functions of
an 'On-line performance & health monitoring system for roadway drivage machines
and circulated internally within British Coal for comments. The full report is detailed
in Appendix 1.
14
From feedback on the report it was suggested that work should concentrate on the
development of a working health and performance monitoring system, which utilised
transducers which were currently available for underground use. It was felt that it
would be inefficient to develop new transducers for specific parts of the monitoring
system e.g machine advance. If a particular problem arose which required
development of a new transducer this then could be investigated as appropriate..
4.3
Performance and Health Monitoring Functions
With the system being based on MACE it can be operated either as a stand alone
underground health monitoring system, or by utilising the underground to surface
transmission link a health and performance monitoring system.
The display facilities available on the MACE unit mounted on the drivage machine
are restricted to textural messages, and parameter measurements. Therefore the
underground information available is restricted to alarm messages and measured
values. These are available in actual transducer signal volts, or derived engineering
units.
Any data analysis for health monitoring and machine performance will be derived by
the surface computer. By carrying out the data analysis at the surface ensures that the
MACE unit utilises the standard monitoring, and communication boards. The surface
monitoring function is detailed later in the report.
4.4
Machine Health monitoring parameters for Underground Trial
To enable a working health and performance monitoring system to be demonstrated

on a Dosco Mk3 roadheader the necessary transducers were identified. The transducers
were limited to those currently available 'off the shelf or ones that could be easily
designed or modified to interface with the MACE system. Table 2 gives a description
of each parameter to be measured and the range required from each transducer. To
reduce the total cost of the transducers it was decided only to monitor one section of
the hydraulic power pack. The Dosco Mk3 roadheader has three pumps, two
Commercial Hydraulics, 2 stage fixed displacement, and one preset variable delivery
pump. The intention was to monitor one of the Commercial pumps and the variable
delivery pump.
The inclusion of a temperature transducer in each of the pump deliveries from the
power pack was to investigate the possibility of predicting problems with the pump
section. By comparing the input and output temperatures of the pump (tank
temperature), over a period of time it was thought it may have been possible to
determine wear and other pump defects by means of temperature differential.
Monitoring of hydraulic line pressure ensures that designed relief pressures are not
exceeded by recording the pressure of a service during a stall. By continually
15
monitoring pressure in the hydraulic circuit, loss in operating pressure can be

identified, which may be due to leakage from hydraulic fittings or damaged hoses can
be identified.
Most pumps on roadheading machines are positive displacement and therefore at a
constant speed of rotation give a constant flowrate. By incorporating a flow transducer
in each supply Une and monitoring the flowrate over an extended time period it should
be feasible to determine increase in leakage and decrease in efficiency.
The use of positive displacement pumps on roadheaders which are manufactured to
high dimensional tolerance, requires the fluid being delivered to be free of
contamination. For this reason all new roadheaders and mining equipment are fitted
with filters in the pump suction lines. It is well known that as the filters become
contaminated the suction pressure decreases and can lead to serious and expensive
pump failures caused by cavitation. To monitor the condition of the suction line filters,
vacuum transducers are fitted in the suction inputs close to the pump inlet. This
ensures that as soon as the pressure drops to a warning level action can be taken to
clear the filters before a major breakdown occurs.
5.0
SYSTEM HARDWARE
The complete monitoring system comprises of 4 distinct sub-systems, MACE, transducers,

data transmission and surface control room equipment.
The complete monitoring system hardware is illustrated in figure 1.
5.1
Multipurpose Automation Control Equipment (MACE)
MACE is a general purpose, intrinsically safe, machine-mounted multi-processor

facility which has been specifically designed to meet the automation requirements of
British Coal for all types of mobile machinery. MACE has been developed as a
standard monitoring and control system which conforms to British Coal's
communications standards, and can accommodate various hardware configurations. For
the roadheader monitoring application the MACE unit comprises of two double
Eurocard size boards.
The monitoring board which interfaces to the keyboard and display and provides
standard I/O (Input/Output), forms the heart of MACE and the underground
monitoring system. It can provide full underground monitoring facilities as a stand
alone system, without the surface data transmission. A back-plane provides both
current limiting and monitoring circuitry for the transducer power supplies as well as
providing noise filtering and transient protection for module inputs.
The communications board comprises two separate microprocessors to handle both the
internal and external communications associated with the MACE module. The
communication board interfaces to the ruggedised MACE modem for trailing cable
16
transmission and MACE data is routed through the modem to the surface gateway PC.
MACE provides the following monitoring facilities :i)
46 analogue inputs with user defined identification labels, alarms, messages

and voltage inputs in the range of 0-0.8 volts. The analogue inputs allow the
connection of any transducer which conforms to BS 5754, 'Specification for
electrical analogue and state signals for use in coal mines'.
ii)
32 digital inputs with user defined identification labels, and alarm messages.
8 of these channels can be configured as pulse counters if required.
The MACE unit is mounted on the roadheader in clear view of the machine operator,
(Figure 2). This enables the operator to be informed of any alarm conditions generated
within the system. The transducer signals are fed to the MACE unit through a number
of junction boxes which are mounted strategically on the roadheader keeping cabling
lengths to a minimum. The junction boxes enable the MACE transducer power
supplies, analogue and digital signals to routed and segregated as necessary.
5.2
Transducers
Once the monitored parameters had been identified the transducers were obtained. All
transducers were 'active' with a power supply of 10 volts and an internal amplifier
providing the signal conditioning to the required voltage output. The advantages of
pre-conditioned transducers are:a)
Simplicity of installation - no need to pre-calibrate;
b)
No risk of calibration interference;
c)
Better electrical security due to transducer and amplifier being housed

together, i.e., no low level signals are outside the unit
For permanent installations underground it is considered that pre-conditioned

transducers are generally to be preferred.
5.2.1 Pressure and Temperature
The pressure and temperature sensors were obtained from Kulite Ltd, of
Basingstoke. These are LS approved and have been used extensively on shearer
monitoring systems. Kulite will provide transducers with pressure and
temperature ranges to suit the application The roadheader monitoring system
required pressure transducers with ranges of 0-1 bar vacuum, 0-500 psi (34
bar), 0-1200 psi (83 bar), and 0-2500 psi (172 bar). All the temperature
transducers operated over a range of 0-120 C.
17
5.2.2 Power Transducers

Davis of Derby flameproof power transducers were used. The signal outputs
conform to BS 5754 and each transducer provides a separate output in the
range of 0.4-2.0 volts proportional to voltage, current and power. The
transducers derive their own power from the 1100 volts to supply the signal
conditioning circuit, and therefore require no external power source. A four
position range selector on the transducer provides ranges of power and current
as shown:
1100 volts
supply
Range
Power
Current
1
2
3
4
100 KW
200 KW
300 KW
400 KW
50 A
100 A
150 A
200 A
The voltage output range of the transducer is 75% to 110% of the supply
voltage 825v to 1210v, the voltage range is not affected by operation of the
power selection switch.
5.2.3 Pressure Switches
To sense operation of the hydraulic circuits identified within the monitoring
specification, 111 Barton adjustable pressure switches were connected into the
relevant hydraulic circuits. The switches had a switching range adjustable
between 13.8-67 bar (200-1000 psi), and a proof pressure of 517 bar
(7500 psi). This allowed the pressure switches to be situated in circuits
operating at either full service pressure (158 bar/ 2300 psi,) or pilot circuit
pressure (34.5 bar / 500 psi).
5.2.4 Filter Condition Monitoring
To monitor hydraulic filter condition, differential pressure switches developed
by PAL filters Ltd were used. The filter indicators operate on a differential
pressure across the filter element. The PAL units are drilled to accept both
visual indicators, and electrical differential pressure switches to allow for
interfacing to a monitoring system.
As the filters elements become clogged the pressure differential increases and
when the pressure difference reaches a predetermined level the indicators are
operated. A relationship exists between oil viscosity and differential pressure,
18
and as viscosity is proportional to oil temperature a false indication of filter

condition is possible at low temperatures. This is accommodated by monitoring
the hydraulic oil temperature in the tank, and ignoring the filter indicators until
the oil temperature reaches a preset value, (typically 30C).
5.2.5 Boom Position
For some of the specified parameters transducers were not available directly
from manufacturers, and these were designed and developed to interface to the
MACE system.
The requirement for boom slew and lift angle was addressed using
potentiometers in a potential divider circuit To achieve a reasonable resolution
over the limited arc moved in both slew and lift, an output of 2.5v - 6.5v was
used representing -90 / +90. 0 representing the boom on the centre line of
the machine in the slew plane, and the boom horizontal in the vertical plane.
A small circuit was designed and fitted with the potentiometers inside a steel
housing. The units were connected via flexible couplings directly on the boom
slew and lift axis. Figure 3 shows the two boom position sensors mounted on
the trial machine.
5.2.6 Flow Measurement
The reliable measurement of flowrate has been a problem for many years
within British Coal mines. The problem has generally been that flow
transducers used in the process industry, designed for precise measurement
have not been robust enough to stand the arduous conditions found within coal
mines. From previous work it was established that a turbine meter used within
the petrochemical industry, designed to withstand pressures of up to 350 bar
(5000 psi), would be the most suitable for use underground. As the turbine
meter produces a pulse output proportional to the flowrate, an interface is
required to convert the output pulses to a voltage signal which the MACE unit
will recognise. It was decided to develop an 'intelligent' interface by utilising
a low power microprocessor to count the pulses, condition the signal and drive
an Analogue to Digital (A/D) converter to produce a voltage output in the
range of 0.4-2.0 volts proportional to the volume of flow measured. Appendix
2 details the development of the flow transducer interface. Figure 4 shows the
flow transducer and interface circuit.
5.2.7 Oil Level
Oil level measurement depends upon the information required. If it is only
necessary to know if the level is 'OK' or 'low' then a digital channel can be
used. Where a multiple of levels are required an analogue transducer is used.
For the monitoring trial the measurement of hydraulic tank level was divided
19
into 3 areas, high, normal and low. The unit used in the trial utilised 3
cylindrical magnetic floats, which operate micro-switches set in a stainless
steel tube at specified levels. An interface circuit was designed to give precise
voltage levels relating to the fluid level in the range of 0.4-2.0 volts. The
design of the level sensor was such that it gave the machine operator an early
warning of a low tank level prior to machine cut-out via the pilot circuit.
5.3 Underground to Surface Data Transmission
5.3.1 Applications Protocol for Boom Type Roadheaders
Control and monitoring activities above and below ground at coal mines
require the transmission of data between items of electrical equipment supplied
by different manufactures. As systems have become more complex the need
for a fast and reliable data transfer has lead to British Coal to standardise on
data transfer protocol. A British Coal specification has been produced to ensure
common electrical standards and line protocol. The British Coal Specification
for Applications Protocol gives details of the data field and applications
protocol in passing data between mining equipment. The data field is
independent of the data communications network, provided that the data
communications network can provide the services required by the application
programs.
MACE utilises a 9.6KB High level Data Link Control (HDLC) transmission
system with the data messages conforming to the data fields specified in the
Applications Protocol specification. To ensure the integrity of data transmission
for the roadheader monitoring system an Application Sheet was constructed,
detailing the specific data transfer requirements for boom type roadheaders, in
particular for the machine to be used in the underground trial.
The 'Application Sheet for Monitoring of Roadheaders using MACE' is given
in appendix 3.
5.3.2 Underground to Surface Data Transmission Link
5.3.2.1
Underground to surface low speed data transmission systems have been used
extensively within British Coal for environmental monitoring for many years.
With the introduction of steering on shearers, faster transmission systems are
now being used. The introduction of data transmission onto mobile plant such
as shearers and roadheaders introduces problems not encountered with static
plant.
20
The main problem with mobile plant is the need to run an extra cable either
along the face line or roadway in a part of the mine where most damage is
likely to occur. The problem was solved in two different ways for the system
70000 data transmission system on shearers by utilising the existing HOOv
trailing cable to the machine. Either a new power cable and associated
termination equipment was used (Type 7s), which included two extra cable
cores specifically for data transmission, or the data was injected at the machine
onto the pilot signal core of the trailing cable and extracted in the gate
roadway at the gate end box. Pilot core transmission being the most likely
method of data transmission of roadheaders, as type 7s cables are less common
amongst British mines.
With the introduction of MACE communication protocol new tests were
required to assess the interaction of the data transmission signal and the safe
operation of the pilot circuit. Tests were carried out on each of the gate end
boxes currently in use within British mines.
The following gate end boxes were tested with all combinations of pilot circuit
being assessed:a)
Wallacetown A67
b)
Wallacetown A74
c)
Wallacetown SIMOS
d)
Baldwin & Francis P130/BZ1
e)
Baldwin & Francis BFS
A report was compiled on completion of the tests and is given in Appendix 4.

5.4 Surface Monitoring System
The usefulness of the monitoring system depends entirely on the information collected
and how the it is presented to the relevant personnel. Therefore it is of utmost
importance that the surface computer system has the flexibility to present the data in
an concise and informative format. TSRE have been recently investigating various
types of SCADA (Supervisory Control And Data Acquisition) software as an updated
replacement for the British Coal SUMMIT system. SUMMIT is a suite of programs
which monitor, store and display data transmitted from below ground relating to
ranging drum shearers fitted with Automatic Vertical Guidance Systems. The
SUMMIT system was becoming outdated due to the underground to surface
transmission system (System 70000) becoming obsolete.
The DEXTERITY SCADA system developed by Nucleus Software was identified as
having theflexibilityrequired by British Coal to provide a good basis for all surface
21
monitoring and control function for the foreseeable future. By the use of appropriate
software interfaces the DEXTERITY system could be accessed by the new data
transmission systems used within the mining industry.
Initially the first DEXTERITY system was configured to emulate SUMMIT for a
shearer trial at Parkside Colliery, with more features being added later.
5.4.1 DEXTERITY Overview
DEXTERITY is designed as an open system offering flexibility and allows the
user to develop their own style of information system, with the facility for
expendability as the system requires. The data collected from the monitoring
system is added to a real-time database which represents the system's view of
the outside world.
Connected to the database DEXTERITY provides a variety of modules that
perform the following functions relevant to the monitoring application:a)
Colour Mimic Displays;
b)
Event and Alarm Handling;
c)
Management Reporting;
d)
Data Logging and Trending;
e)
Complex Calculations;
f)
Data Transfer to other computers;
g)
Authorization Levels of Access;
Other modules are provided, which deal with the control aspects of the
SCADA package.
The graphics interface provides three autonomous areas for general mimic
display, alarm annunciation and command dialogue. Full screen menus can be
created and form the basis for addressing the system. The mimic can be a
mixture of both static and dynamic picture elements. Dynamic elements
provide the means for animation using text displays, colour and position
control. Static elements include text, symbols, lines boxes, circles and other
geometrical objects.
For system configuration and user-function programming is achieved through
a programming language modelled on 'BASIC'. This provides the programmer
access to all the DEXTERITY modules and enables interaction with the
database, enabling the generation of an application specific system.
22
The networking and authorization facilities provided by DEXTERITY make

it ideal for colliery multi-user applications, were each member of management
staff is provided with a VDU terminal. Allowing them to interrogate each
application as required.
5.4.2 Surface Hardware for Roadheader Monitoring Trial
The surface hardware comprises of a surface interface unit, a IBM compatible
PC and a DEC systems VAX station 3100. The surface interface unit
incorporates the isolation barriers between the underground transmission and
the surface transmission systems. The surface interface converts the MACE
HDLC protocol into RS 232C protocol which is then converted by the PC
which act as a gateway onto to an Ethernet ring. The PC conversion software
has been developed at TS RE to enable multiple system to be accessed through
one VAX station terminal.
For the roadheader project it was intended initially to use the roadheader trial
to assess the PC version of DEXTERITY currently being developed by
Nucleus Software. The PC DEXTERITY system operated under UNDC and
provides all the function of the VAX system but for reduced hardware &
licence cost.
Unfortunately the lack of manpower and experience of the PC system lead to
the change to a VAX station based system. A VAX 3100 was purchased and
the PC already acquired was configured to act as the gateway.
M
SURFACE SOFTWARE & CONFIGURATION
The interface between man and computer systems relies heavily on the visual representation
of the information retrieved.
To identify the requirements of the surface system a surface monitoring functional
specification was produced for discussion. The functional specification describes how the
performance and health data transmitted from the roadheader was to be displayed to the
system operator. The displays detailed in the specification are specifically designed for the
underground trial at Middleton mine. The displays detailed are likely to form a base for a
colliery based system but is probable that as experience is gained and other system
requirements are identified the displays will be added to and modified.
The functional specification for the surface monitoring system is given in Appendix 5.
23
The surface displays either relate to the four areas of roadheader monitoring :a)
Real-Time Machine Performance;
b)
Historical Machine Performance;
c)
Real-Time Machine Health;
d)
Historical Machine Health;
6.1
Real-Time Machine Performance Displays
The display shown in figure 5 is the main monitoring system display is designed to
act as the interface between operator and monitoring system. The display was designed
to be self explanatory, enabling a novice to easily access each part of the monitoring
system.
The roadheader mimic is constructed from boxes which represent major parts of the
underground monitoring system, ie. Power Pack, Boom, Cutter Motor, etc... Using a
mouse the display relating to each item can be selected by 'clicking' on the relevant
box. Where the box is used to represent the operation of an item of equipment which
can be either operating or stood, then the colour of the box is used to represent the
current state of that item of equipment. For example the box is magenta when the item
is stood and changes to green when the item is in operation. Text messages are also
included in the boxes to describe the item of equipment represented and these indicate
for example 'cutter motor on' when running, and 'cutter motor stood' when not. Other
boxes represent the health of a particular parameter, for example the box representing
the filters will change from green in colour to red if one of the filters becomes
blocked. A red box indicating a alarm condition has occurred. From this display a
indication is given to the system operator the current machine utilisation, and any
immediate alarm conditions at a glance.
The next real-time performance display is a representation of the boom position, (see
figure 6) and provides the system operator with an indication of current cutting
parameters. By leaving this display on the terminal screen it is possible to identify
where the machine operator is currently positioning the boom and wether the boom
is being used for cutting which is represented by a green circle, or not cutting
represented by a red circle. The circle indicating the position of the cutting head with
respect to the machine and a reference profile.
The final real-time performance display gives an indication of the current state of the
debris clearance system (figure 7). Each box representing an item of the debris
clearance equipment. The box changes colour form magenta to green depending on
if the item is operating or stood.
24
6.2
Historical Machine Performance Displays
Two historical machine performance displays were specified in the function

specification for the surface monitoring system. Both were configured for the system
but the 'Machine Advance and Running History' was compiled into one graph.
The Machine Utilisation (hourly) display was configured as described apart from
changing over the positions of 'm/c cutting' and m/c cutting & loading, on the vertical
scale. Figure 8 shows how the display represented a cutting period during the
underground trial at Middleton Mine. The options for the machine utilisation were
allowed to be expanded such that the three time options given previously could be
accessed by the system operator.
The 'Machine Advance and Running History' display caused some problems in the
assessment of drivage cycles at Middleton Mine due to the debris loading facility
being dependent on a free steered dumper wagon. When the debris clearance system
is continuous conveyor belts the display is expected to perform better. It became
apparent during the underground trial that further development on configuring the
surface system was required to ensure correct display operation.
A third display was added to the historic performance options which allowed all
performance operations to be represented as a percentage of the shift time. Figure 9
illustrates the initial concept of the display with the different size boxes indicating the
respective times. The actual display always reaches 100% unless an indeterminate
situation arises, ie lost of transmission from the MACE unit. Figure 10 shows an
actual display over a one shift time period. Unfortunately the underground trial was
not run on consecutive shifts as a colliery drivage would be and a extended time
period display for the trial was not available. However Figure 11 gives an indication
of how multiple shifts can give a representation of machine utilisation.
6.3 Real-Time Health Monitoring Displays
All monitored parameters on the roadheader can be displayed on demand. The system
operator is presented with a list of all available transducers and prompted to choose
4 parameters for display. The operator has a choice of wether to display the current
values in text or thermometer display. Figure 12 shows a thermometer display for the
first stage of a hydraulic pump. The thermometers represent supply pressure, suction
pressure, flowrate and supply temperature. The two bars on theright-handside of each
of the thermometers represent maximum and minimum values, during the display
period.
To enable the system operator to have clearer understanding of a transducer's location
on the machine, the 3 main service functions have an individual display;
6.3.1 Hydraulic Services
Figure 13 shows the display for the hydraulics services, for one of the
25
Commercial Hydraulic pumps. The display allows the system operator to see
at a glance the current transducer reading attached to the pump. If an analogue
parameter enters an alarm state the alarm if signalled to the operator in the top
section of the screen. If a filter becomes blocked the alarm is signalled and an
the box representing the filter unit turns from green (OK) to red.
6.3.2 Electrical Services
Figure 14 illustrates the electrical services display which provides the system
operator with the current electrical requirements of the roadheader. Any
transducers associated with the electrical services are included on the display
i.e motor temperature, and water flow.
6.3.4 Water Services
Figure 15 shows the water circuit display for a typical roadheader, allowing the
system operator to assess the current state of the water requirements. The
system illustrated incorporates high pressure water cutting equipment, and air
movers for degassing and dust suppression. The trial was fitted with a very
basic water circuit which could be represented by inlet pressure and flow.
6.4
Historical Health Monitoring Display
All the monitored parameters are logged at a pre-selected time interval onto the
surface computer hard disc drive. This provides the system operator with the facility
to recall any of the parameters for trend analysis. The system operates on the principle
of first in first out with new data over-writing the oldest data on the disc. The current
capacity of hard disc drives (>120MB) enables weeks of data to be stored before
over-writing occurs. The system operator can select up to 4 individual parameters and
has the standard time scale options. Figure 16 shows a trend graph of 4 transducers
over 1 hour of machine operation.
7.0

7.1
Middleton Mine Site Description
The monitoring system was to be fitted to a Dosco Mk3 roadheader at TSRE's

underground trial site at Middleton Mine, Wirksworth, Derbyshire. Middleton mine
is one of the largest limestone mines in Europe and has been used by TSRE for the
testing of various pieces of underground machinery for almost 20 years. The limestone
is very pure and offers good tough homogeneous strata for underground trials
involving cutting. The mine environment is not subject to the strict electrical
requirements for equipment that British Coal mines are, and therefore allows prototype
equipment to be tested and modified before electrical approval is applied for.
26
For the trial a previously cut tunnel of approximately 40m was to be used. This
allowed the installation of a monorail mounted bridge conveyor at the rear of the
machine. The bridge conveyor is the last part of the system being monitored before
transferring to the mine conveying system, which is controlled and monitored
independently from the surface.
7.2
Trials Machine
The Dosco Mk3 is a 71 tonne roadheader used mainly for cross measure development
drivages. The machine was owned by TSRE and had been used previously for other
roadheader trails, but had done a relatively small amount of drivage length, and was
in a good state of repair. Because of commitments within British Coal it was decided
that the Mk3 roadheader should be transferred to Clipstone colliery to be used on
major development drivage, and that another roadheader would be provided which
would be suitable for the monitoring trials at Middleton.
A replacement Anderson Strathclyde RH1/4 roadheader was made available from a
Colliery. The RH 1/4 is of similar design and size to the Dosco Mk3 weighing
approximately 90 tonnes. Figure 17 shows the RH1/4 in the trial site tunnel at
Middleton mine. The roadheader was removed from the colliery and sent for
refurbishment at Anderson Strathclyde, Glasgow. The machine was broken down into
it's major components and overhauled as necessary. On re-assembly the new hoses
were used throughout the hydraulic circuits. To enable boom slew position to be
measured the boom turret was machined to incorporate an axial shaft for the slew
transducer to be driven from. Modification to the boom lift axis and mounting brackets
made at Anderson Strathclyde to enable boom lift to be measured.
Initially in early 1991 brackets and transducers were acquired to install the monitoring
system to the Dosco Mk3 roadheader and installation of the equipment had started
before the machine was required elsewhere within British Coal. Although the majority
of the transducers were compatible for both roadheaders, new brackets would be
required for mounting the equipment. To take account for the delay in acquiring the
RH 1/4, having it refurbished, designing the mounting brackets and fitting the
monitoring equipment, a 6 month extension to the project was applied for and granted.
The two machines have a few different functions which are relevant to the monitoring
system. The Dosco Mk3 has an apron which can sump into the debris pile to assist
in clearing the cut material. The Anderson RH 1/4 has a telescopic boom which is
designed to assist the machine operator in starting the cut of the next section of
roadway. Operating pressures and hydraulic flowrates are slightly different on the
RH 1/4 requiring further configuration of the MACE software. Both roadheaders have
two rotary gathering arms mounted on a lifting apron, and an armoured conveyor
passing through the centre of the machine for debris clearance. On the Dosco the left
and right gathering arms are operated under independent hydraulic control, and the
chain conveyor is electrically powered. On the RH 1/4 the gathering arms and chain
conveyor are operated from a single hydraulic control valve. Therefore a single
pressure switch is all that is required to access the operation of machine debris
27
clearance system on the RH 1/4, whereas two pressure switches and a power transducer
where required to monitor the same functions on the Dosco Mk3. The surface
DEXTERITY monitoring system was modified to accommodate the changes between
the different machines.
7.3
Site preparation and Installation of the Monitoring System
The RH 1/4 roadheader was delivered to Middleton Mine on the 1st December 1991.
The trial site required a number of services supplying to the tunnel before the
roadheader was installed. Water was routed to the site to provide for dust suppression
and motor cooling. A 240 volt supply was required to power the MACE power supply
as no 1 lOv or 240v supply was available on the roadheader. A monorail was installed
in the rear part of the tunnel to enable the bridge conveyor to advance behind the
machine and discharge properly into the mine dumper for debris removal.
Initially the intention was to house the surface computers outside the mine in a
suitable secure office in the mine's main office block. With a transmission cable being
run from below ground to the office over a length of about 1km. Due to lack of time
and the problem of crossing a minor road it was decided it that would be better to
install the surface system within the mine in a stand alone building. Previous tests had
been performed on the transmission system to ensure correct operation over distances
of a few kilometres and it was of little significance if the Middleton trial used a
transmission length of 50m or 1km. The other benefit of having the surface system
nearer to the roadheader enabled the project engineer to be aware of the machine
operators actions, and if a problem occurred with the system the engineer was on hand
to facilitate any action.
As soon as all the transducers, mounting brackets and associated monitoring
equipment were available at Middleton mine, work commenced on preparing the
machine to accept the monitoring system. The first stage was to identify each
hydraulic circuit and install the relevant transducers. All the transducers and machine
mounted hardware were fitted to the machine so that it was easily accessible. This
helped in identification of problems, and made the system easily identifiable to any
person visiting the site. The pressure switches used to assess the operation of the
tracks, apron, rear jacks, bridge conveyor and chain conveyor were mounted behind
the driver and are shown in figure 18. The pump monitoring equipment was mounted
at the rear of the machine shown in figure 19. The visual tell tale filter condition
monitors mounted in the hydraulic filter bowls were replace with the differential
pressure switches, see figure 20.
The trial RH 1/4 roadheader water circuit was rudimentary without any machine
interlocks installed. The water was fed to the machine at increased pressure from a
small mono pump at 500 psi and an available flow of 10 gpm. The water passes
through the oil coolers, power pack and cutter motors before being exhausted through
the dust suppression sprays. Although a typical water circuit display was designed for
the surface system, (see figure 15) only inlet water pressure and flow were measured
28
on the trial machine,figure21 shows the pressure and flow transducer mounted on the
roadheader.
The next part of the installation was to split the 1100 volt supplies to the cutter and
power pack motors to enable the power transducers to be installed in the circuit. The
power pack, power transducer, ruggedised modem and MACE FLP power supply unit
were mounted as shown in figure 22. After fitting the MACE unit by the machine
drivers position,figure 2, and the junction boxes figure 23, the system was ready for
connection.
Connections to the MACE unit are through 7 double-density 25 pin connectors, with
power supplied to the unit via a single 6 way connector, all of which are manufactured
by AB Connectors. The Analogue channels utilise 2 connectors, the digital inputs and
the transducer power supplies use one each. The other 3 are for control signals out of
the unit and are not required for the monitoring application. The MACE unit has a
number of power supplies available for transducers, there are 12 dedicated 8.192v
supplies whose current drain is individually monitored and is not allowed to exceed
8mA. There are also 4, general purpose 10 volt supplies which allow the connection
of transducers up-to a current limit of 50ma. Each of the lOv supplies has it's own Ov
return path and the transducers must be connected such that the correct return is used
depending on the supply utilised. To ensure correct connection of the transducers it
was necessary to design 4 junction boxes which would be mounted on the machine
at appropriate points. The position on the machine of the junction boxes was such that
it kept the individual transducer cables to a minimum length, and the return to the
main junction box was via 25 core cable. Figure 20 illustrates the junction box
allocation and cable requirements for the monitoring system.
The junction boxes were mounted on the machine, but due to the fact that the junction
boxes were designed and manufactured before the change of roadheader, the junction
box lay-out for the Dosco Mk3 was such that the junction boxes would have been
mounted at different points of the roadheader. The design of the RH 1/4 was such that
it was possible to mount 3 of the junction boxes on one plate and still keep short
transducer cable lengths, see figure 19. For the purpose of the trial at Middleton mine
and to keep the cost of cabling and connectors at an acceptable level for the trial
standard 'D' type connectors were used between the junction boxes and some of the
transducers. For a system operating in a coal mining environment sealed 'Lemo' or
'AB' connectors should be used throughout For cable protection stainless steel
braided conduit or hose type cables should be utilised.
The surface computer system was installed in a purpose built building close to the trial
site entrance. A length of 4 twisted pair type NCB spec 429 telecommunication cable
was run directly between the ruggedised modem on the machine and the surface data
handler unit The gateway PC and VAX station had previously been installed with the
relevant software.
29
SYSTEM COMMISSIONING
The complete system was ready for commissioning in July 92. The first part of the
commissioning was to test the machine to surface transmission link. To simulate the
transducer inputs a MACE test box was connected to the MACE unit. The surface system was
started and by varying the inputs to MACE unit the surface link was proven. The MACE unit
was then isolated from the surface system, and each transducer input was tested to identify
any wiring faults. This was done by connecting a 1 volt signal at the appropriate junction box
connector, and configuring the MACE unit to display the channel under test in volts. The
majority of the inputs were found to be wired correctly with very little voltage drop. Due to
ambiguous connection details on the Lemo connectors fitted to the Kulite pressure and
Temperature transducers, it was found necessary to re-wire the connecting cables between
transducer and junction box.
Once all the wiring had been checked and faults corrected it was necessary to set the pressure
switch levels to ensure correct identification of service operation. On the Dosco Mk3 most
of the major hydraulic services are pilot operated, The pressure switches would be subject to
a maximum pressure of 350 psi, and be required to switch 'on' above 300 psi and 'off' below
300 psi. The RH 1/4 has very few pilot operated circuits and the pressure switches must be
capable of operating at pressures up to 2300 psi. Fortunately the 111 Barton pressure switches
used in the project had a proof pressure of 7500 psi and an adjustable switching range
between 200 and 1000 psi. The RH1/4 pilot circuit pressure is 500 psi so the switches
operating on pilot circuit pressure were set to 350 psi and the switches on the main supply
circuits were set to 1000 psi switching level, all of which gave satisfactory results.
When all the equipment had been commissioned on the machine the surface system was
connected and the complete system was ready for re-testing.
M
SYSTEM TESTING
System testing was conducted by instructing the machine operator to cut the section of tunnel
in a standard cutting pattern. During cutting checks were made to the surface system to ensure
that all parameter were being transmitted and processed as specified. A few modifications
were required to the boom position algorithm to change the sign of an axis, and to ensure the
circle representing the cutting head stayed within the cutting profile on the screen. Once
cutting had started it became apparent that the threshold of 'cutter power' used to determine
cutting was too great, and the algorithm was adjusted accordingly. A few minor adjustments
to the digital parameters which arose from the change in roadheader were needed to ensure
the correct operation of the displays.
The next stage of the trial was to cut a few metres of roadway and use the surface system to
monitor the data, and then examine the historical displays to ensure each operated according
to specification. Unfortunately due to time restrictions, man power and other commitments
within British Coal only 5 metres of drivage were cut over a period of 3 weeks. This amount
of cutting helped to prove the system within the limitations of the trial period and equipment.
The main difference in the underground trial site and a coal mine drivage was the debris
clearance system. After the bridge conveyor a 2 tonne capacity site dumper was used to
30
remove the debris from the trial site tunnel. This required the machine operator to stop the
debris clearance system and wait until the dumper returned before more debris could be
removed. Thereby greatly increasing the time taken for loading out of cut material. The stops
and starts of the debris clearance system are noticeable in the machine utilisation display,
figure 8.
During the cutting trial a few problems were experienced with the data transmission from
MACE with the data link becoming disconnected. The problem was rectified during testing
by resetting the MACE unit. The problem was identified as being faulty connections with the
IC sockets on the communications board. Better quality sockets were used to replace the
existing ones and no further trouble was encountered during the trial.
10.0
CONCLUSIONS AND RECOMMENDATIONS
Although only a limited amount of cutting was done enough information was gathered to
enable assessment of the monitoring system. The whole system was shown to offer a great
improvement over previous attempts to monitor roadheading machines. No problems were
experienced within any of the transducers or machine mounted hardware. The surface
equipment and DEXTERITY proved it's flexibility in another application, and illustrated that
given the right data that roadheader and drivage information can be presented in a clear and
concise format.
The only noticeable problem with the surface software was the algorithms connected with the
current cutting time, and determining the start of a cutting cycle. The current cutting time
display algorithm would start and stop as specified but for some reason which is being
investigated, the part of the algorithm controlling the cutting time display incremented
erratically. Actual historical times recorded for cutting were not affected by the display of
cutting time as these use the system clock.
Due to the limited amount of cutting actually achieved the historical display used to represent
'actual cycles cut' could not be assessed for correct operation. When the system is installed
at a colliery were a significant number of metres are cut during the life of a drivage, a better
analysis of the machine advance history can be made. The other historical displays 'Machine
Utilisation' (see figure 8) and 'Machine Percentage Utilisation' (See figure 10) provided the
information in the concise and clear format as specified.
For the monitoring trial all the displays operated reliably and provided the information to the
specification for the trial application. It must be remembered that the flexibility of the
DEXTERITY package enables displays to be configured to almost any application and present
the information in any format. This offers flexibility to a colliery based system which up to
now has been unavailable. If any machine parameters are identified which are not already
available, a dedicated display could be devised to suit the application. Although the trial
system was specified for a single boom type roadheader the flexibility the system offers does
not restrict it solely to this type of mobile plant. With some configuration modifications the
system could be adapted for use on twin boom roadheaders and multi boom drilling machines
etc.
31
Further work on transducer technology for use within British Coal mines could ensure MACE
offers total flexibility in the monitoring of mobile plant. The application of low power single
chip microprocessors could enable compact transducers conforming to BS5754 to be
developed cheaply.
It became apparent form the underground trial that a basic monitoring system could provide
the majority of performance data by utilising two power transducers and the pressure
switches. The health monitoring transducers could be specified to satisfy a colliery's needs,
and as more information is required the system offers full expansion capabilities.
For the system to be available for use within British Coal mines it must first be certified for
intrinsic safety. This must cover MACE the associated transducers, hardware and pilot core
data transmission system. Once certified the system offers unrivalled facilities in 'on-line'
monitoring and management information for roadway drivages and provides an area of
monitoring which has so far been unavailable within British Coal mines.
32
Supervisory
Computer
DEC
VAX Station
Figure 1. ROADHEADERS MONITORING SYSTEM

Ethernet
PC Gateway
RS232
Surface
Interface
EZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZ2Z2Z2ZZZZZZZZZZZZZZZ^ZZZZZZZZZZZZZZ22221
LS.
Type 492
Telephone
Cable
MACE HDLC
9.6kb/s
MACE HDLC
ROADHEADER
MACE
Modem
Gate-end
repeater
E-Type
DC2
Power
Supply
Figure 2. MACE Unit Mounted on RH1/4 Roadheader
34
Figure 3. Boom Position Sensors Mounted on Roadheader
35
%f. , . . , . . , i^p^lÎJgplPlIJI
gf
ii '
Figure 4. 'I ntelligent' Flow Transducer and Interface Circuit
36
Figure 5. Current Machine Utilisation Display
37
Figure 6. Current Boom Position Display
38
Figure 7. Debris Clearance System Display
39
Figure 8. Historical Machine Utilisation Display
40
MACHINE UTILISATION
WEEKLY
MACHINE UTUSATION
% OF SHIFT TIME
STOOD
JZZI RUNNING
LOADING
100-
CUTTING
H
CUTTING k LOADING
50 -
Figure 9.
Illusration of Machine Percentage Utilisation History
Figure 10. Actual Display of Machine % Utilisation
42
Figure 11. Machine % Utilisation, Multiple Shift Display
43
Figure 12. Transducer Thermometer Display
44
Figure 13. Hydraulic Services Display
45
M/C ELECTRIC SERVICES

M/C VOLTS
0000 V
4*
TEMP
000 C
Figure 14. Illustration of Electrical Services Display
Figure 15. Typical Water Circuit Display
47
Figure 16. Transducer Trend Graph Display
48
Figure 17. RHl/4 Roadheader at Middleton Mine
49
Figure 18. Pressure Switches Mounted on Roadheader
50
Figure 19. Pump Supply Monitoring Transducers
51
Figure 20. Filter Condition Monitoring Sensors
52
Figure 21. Water Circuit Flow and Pressure Transducer Mounted on Roadheader
53
^*^|
Figure 22. Power Transducer, MACE PSU & Ruggedised Modem Mounted on Roadheader
54
Figure 23. Junction Boxes Mounted on Roadheader
55
- D PU
MACE UNIT
P I 2 Q P U C S K4Q PL5
^
I
.1
|1
SK7
U
I
I
J
I
I
I
MULTICORE 2 5 TAY
ANALOG
JUNC
BOX 1
MULTICORE = 8 WAY
ANALOG
JUNC
BOX 3
tn
*- P1PR
L p1Tp
L P2PR
-
P2TP
I P1SC
P2S C
PIFL
P2FL
Figure 24.
L P3PR
P3TP
P3S C
PPPff
P3FL
MACE Wiring Details for Roadheader
UNDERGROUND
TO S URFACE
TRANSMISSION LINE
Table 1. Monitoring Parameters for Consideration

* Denotes parameters to be monitored initially by Drivage Machine Performance & Health
monitoring development system using MACE.
BOOM
Cutting Head
Water Jets
High Pressure Jets
Dust suppression Jets
Picks Wear
Position
Dust Suppression System
System Air movers
Boom Cutter Gearbox
Mechanical Cond'
Oil Debris Analysis
Mechanical Vibration
Oil Level
Oil Temperature
Water Contamination
Mine Material Contamination
Lubricant Flow (If Applicable)
Boom Cutter Motor
* Power Requirement
* Free Running
* Overload
Thermal Cutout Temperature
Mechanical Cond' Bearings
* Cooling Water Flow
Temperature
Speed
Direction of Rotation
Boom Slew & Elevate
* Position
Mech Cond'
Leakage
Trunnion Brgs Worn/Loose
Slew Ring Condition
57
Table 1. Continued, Monitoring Parameters for Consideration

APRON & CONVEYING SYSTEM
Apron
* Operation
Lift Cylinders Leakage
Sump Cylinders Leakage
Gathering Mechanism
* Operation
Mechanical Cond'
Hyd Motors Leakage
G/A Gearbox Condition
Lubricant Cond'
Lubricant Level
Conveyor System
Elee Drive Motor
* Power Requirement
Free Running
Overload
Mechanical Cond'
Bearings
Cooling Water Flow
Temperature
Speed
Conveyor Gearbox
Gearbox Mech Cond'
Lubricant Cond'
Lubricant Level
Torque
Scraper Conv
Chain Mech Cond'
Tension
Tension Mechanism
58

HYDRAULIC CIRCUITS
Power Pack
Electric Motor
* Power Requirement
Free Running
Overload
Mechanical Cond'
Bearings
* Cooling Water Flow
Temperature
Speed
Hydraulic Pumps
* Mech Cond'
* Efficiency
Wear Cavitation
* Pressure
* Flow
Speed
Vibration/Noise
Hydraulic Services
Hose Leaks
Bursts
Connections
Valves Mech Cond'
(Types)
Manual
Servo
Solenoid
Pilot Operated
Flow Divider Mech Cond'
Flow
Pressure
Vibration/Noise
59

HYDRAULIC CIRCUITS Continued..
Pilot Circuit
* Pressure
Leakage
Hydraulic Filters
* Condition
Suction Filters
* Condition
*
*
*
*
Pressures in Circuit
Flows in Circuit
Temperatures in Circuit
Relief Valve Settings
Hydraulic Tank
Hydraulic Fluid
Water Content
* Level
* Temperature
Orifice Test Unit for RCM * Pressure and Flow Monitoring on-line
60

CATERPILLAR TRACKS
Left & Right
Hydralic Motors
* Operation
Mech Cond'
Leakage
Torque
Speed
Drive Gearbox
Grbx Lubricant Cond'
Lubricant Level
Mech Cond'
Bearings
Chain Drive
Track Mech Cond'
Tension
Tensioning Mech'
Ram Cond'
Ram Pressure
Spring Cond'
Spring Tension
61
Table 2. Machine Variables Real and Derived

Real Analogue:Tank Oil Level
Boom Slew Angle
Boom Lift Angle
Pump 1 Supply Pressure
Conveyor Tension Pressure
Conveyor Operating Pressure
Pump 1 Suction Pressure
Pilot Circuit Pressure
Cutter Motor Temperature
Pump 1 Supply Temperature
Hydraulic Oil Temperature
Pump 1 Flowrate
Pump 2 Flowrate
Pump 3 Flowrate
Water Circuit Flow
Water Circuit Pressure
M/C Voltage
Cutter Motor Power
P/Pack Motor Power
Chain Conveyor Power
0.4 - 2.0 volts

+/- 45
+/- 45
0 - 2500 psi
0 - 2500 psi
0 - 2500 psi
0 - 1200 psi
0 - 2500 psi
0 - -1 bar
0 - -1 bar
0 - -1 bar
0 - 500 psi
0 - 120 C
0 - 120 C
0 - 120 C
0 - 120 C
0 - 120 C
0 - 30 gpm
0 - 30 gpm
0 - 30 gpm
0 - 20 gpm
0 - 700 psi
0-1100 volts
0 - 200 Kw
0 - 200 Kw
0 - 100 Kw
Gathering Arm Left hand

Gathering Arm Right hand
Bridge Conveyor
Apron Sump (in)
Apron Lift (up)
Rear Jacks (down)
L.H Track (frwd)
R.H Track (frwd)
L.H Track (bkwd)
R.H Track (bkwd)
Pump 1 Pressure Filter
Return Line Filter
on/off
on/off
on/off
on/off
on/off
on/off
on/off
on/off
on/off
on/off
ok/blocked
ok/blocked
ok/blocked
ok/blocked
New
MK2
Real Digital:-
62
New
New
Table 2. Continued.. Machine Variables Real and Derived

Derived Variables for use by DEXTERITY
Required Parameters
Derived Analogues:Boom Position (X,Y)
Boom Slew & Lift
Cutter Head Position
Boom Slew & Lift
% of Face Cut
Current Cutting Time

Cutter Motor Power
% of Face Cut
P/Pack Motor Run Time
P/Pack Motor Power
M/C Run Time % of Shift
P/Pack Motor Power Run Time

Shift Time
Derived DigitaliMachine Utilisation

Machine Cutting
Cutter Motor Power

Boom Position
% of Face Cut
Machine Cutting & Loading
Cutter Motor Power

Boom Position
Gathering Arms
Chain Conveyor
Bridge Conveyor
Machine Loading
P/Pack Motor Power

Cutter Motor Power
Boom Position
Gathering Arms
Chain Conveyor
Bridge Conveyor
Machine Running
P/Pack Motor Power
Machine Stood
P/Pack Motor Power
63
Table 2. Continued.. Machine Variables Real and Derived

Machine Operation
Machine Cycles
Number of Faces Cut
Machine Advance
Machine Tracks or
Advance Transducer
64
APPENDIX 1
BRITISH COAL
INTEGRATED SYSTEMS
ON-LINE PERFORMANCE & HEALTH MONITORING FOR ROADWAY DRIVAGE

MACHINES
TECHNICAL SERVICES & RESEARCH EXECUTIVE, ASHBY ROAD, STANHOPE,

BRETBY, BURTON UPON TRENT, STAFFS DE15 OQD
CONTENTS
1. Introduction
2. Monitoring System Overview
3. Monitoring System Requirements
4. Performance Monitoring for Drivages
4.1 Machine Cutting
4.2 Debris Clearance
4.3 Supports Set, lagged and made secure
4.4 Machine Advancing
4.5 Services Extended, Machine Serviced & Stoppages
4.6 Performance Monitoring Conclusions
5. Drivage Machine Health Monitoring
5.1 Oil & Hydraulic Fluid Levels
5.1.1 Hydraulic Oil Level Measurement
5.1.2 Lubrication Oil Level Measurement
5.2 Hydraulic Fluid and Oil Contamination
5.3 Hydraulic Filter Condition Monitoring
5.4 Hydraulic Power Pack and Circuit Monitoring
5.5 Measurement of Water Circuit
5.6 Electrical circuit Monitoring
5.7 Health Monitoring Conclusions
6. Surface Installation and Software
7. Programme 1990/91
FIGURES
1. Drivage Cycle
2. Detecting the Operation of Hydraulic Circuits
3. Power Pack Monitoring
4. Typical Roadheader Hydraulic Circuit
5. Typical Roadheader Water Circuit
6. Programme of Work
TABLES
1. Monitoring Parameters for Consideration
2. Performance & Health Monitoring Transduers
69
Summary
The monitoring facility for roadheading machines is generally poor within British Coal mines,
most monitoring systems have been developed for either shearers or environmental
monitoring. With the changes to retreat working more emphasis on drivage rate has generated
interest in the measurement of the performance of roadheaders and drivage equipment. The
operation of driving a roadway is cyclic in nature and to enable an accurate analysis of the
drivage to be performed, and displayed at the surface, each part of the cycle must be
separately identified. As part of the monitoring system for roadheaders project, the parameters
important to collieries for performance monitoring and health monitoring have been identified.
It is intended to develop a monitoring system to which will provide both performance and
health monitoring and transmit the collected data via the MACE modem to a surface console.
Initially the standard MACE monitoring and communications boards will be used for data
aquisition and transmission. A surface computer will be used to analyse and store both
performance and health monitoring data.
The surface computer will be a workstation running the latest proprietary monitoring package,
with the displays representing the data in an informative and comprehensible format. The
surface computer will initially analyse and record the data giving similar information as that
provided for shearers by SUMMIT.
A complete system will be commissioned on the Dosco MK3 roadheader at Middleton Mine
for surface trials during 1991.
71
1. Introduction
British Coal has invested heavily in systems for monitoring, and sometimes controlling,
underground equipment and the environment from the surface. The benefits have been widely
appreciated and extensively used to make underground operations more visible to management
and to provide the means for recording events for later analysis.
The MINOS system was introduced initially to deal with the complexities of monitoring coal
clearance bunkers and the control of conveyors, up to the AFC, and has been developed to
include underground environmental and static plant monitoring. Gradually this form of
monitoring from the surface has encompassed most important operations and has now
extended onto the coal face.
The introduction of Shearer Guidance with MIDAS/DIAM and PATHFINDER brought with
it a dedicated monitoring package called SUMMIT, which undoubtably contributed to the
success of shearer control by providing general visibility of the shearer operations. This
represented a breakthrough in the monitoring of a shearer cutting cycle and has been widely
appreciated.
In comparison, the monitoring of roadway drivages has taken a lower priority and is not
accessible enough to any of the surface monitoring systems. Recent concern over the
productivity of some drivages and the lack of improvement in performance in general terms,
has indicated a need for urgent attention to the monitoring activity and to study in detail the
potential for action.
The purpose of this report is to detail how a monitoring system for roadway drivage can
recover valuable information for shift time analysis and to measure the key health condition
parameters of the drivage machine.
2. Monitoring System Overview
It is intended to use a MACE (Multi-purpose Automation and Control Equipment) module
as the data collection unit, and mount it local to the machine operator. The MACE module's
compact design and flexibility makes it ideal for applications incorporating monitoring and
control on mobile plant. MACE offers a standard monitoring board which allows the data
aquisition and display of upto 46 analogue and 23 digital configurable inputs. The initial
monitoring trials will concentrate on data collection for machine and drivage performance
utilising this monitoring board.
MACE offers excellent expansion capabilities and in the future, application boards could be
developed to extended the systems faculties to include the control of roadway profiling,
alignment, load control and to extend the monitoring facilities. If the prototype system proves
successful, MACE could provide the mechanism for an integrated system for drivage
machines.
The surface transmission system will use the trailing cable modems and interface to a new
surface software data collection package. Surface software will most likely be based on one
of the propriety SCADA (Supervisory Control and Data Aquisition) packages currently being
assessed.
73
3. Monitoring System Requirements

The output of a monitoring system has to satisfy personnel at different levels of the colliery
structure, from the machine operator to the colliery manager. Each level will require the
information to be presented in different formats, with some data interrogation available on the
machine and other data presented using the surface displays.
The Colliery Manager will be generally interested in the daily performance of the drivage
machine, particularly the drivage rate, machine utilisation and reasons for major stoppages.
This type of monitoring is directed towards the performance of the machine and drivage and
will be displayed on the surface. Figure 1, shows the cyclic nature of a roadway drivage, each
part of the cycle must be separately identified to enable an accurate time analysis of the
drivage to be performed.
The machine operator or underground craftsmen are more likely to be interested in the
condition of the roadheader's services, ie oil levels, filter conditions and reliable operation of
the hydraulic, water, and electrical services. This information will be presented to the drivage
team on the machine to help with diagnosis and maintenance duties, with alarms to indicate
fault conditions.
The colliery mechanical and electrical maintenance departments will require information on
the surface from both the performance and condition monitoring functions, with a view to the
management of maintenance resources and for planning and provisions for machine downtime.
From discussions with staff at collieries and within Technical Department the current most
beneficial function of a drivage monitoring system is the ability to analyse the cyclic
performance of the machine and drivage, with secondary importance to health monitoring. It
was also stressed that for a monitoring package to be successful the information retrieved
must be presented in a concise and practical format, both underground and at the surface.
The data output of the roadheader monitoring system can be broken down into three
categories, the requirements of which can be identified and given priorities. The main
categories of a roadway drivage monitoring system are:1. Cyclic Performance of the Machine and Drivage.
2. Machine Health Monitoring.
3. Surface Information System
4. Cyclic Performance of Machine and Drivage
The objective of a performance monitoring system on roadway drivages is to make the
drivage as visible at a surface console as that currently available from SUMMIT for the coal
face. By examination of a typical drivage it can be seen that the operation of driving a tunnel
can be split into five different parts, four of which form the drivage cycle and must be
identified separately to enable the performance of the drivage to be presented. The fifth part
of the drivage which must be performed at regular intervals is the extension of the electrical,
water and material handling services.
74
By installation of suitable transducers, correctly positioned within the machines hydraulic and
electrical services, the information needed to identify the different parts of the drivage cycle
can be obtained.
The following parts of this section illustrate the information required and how the information
will be collected for analysis on line to give an overall view of the drivage.
4.1 Machine Cutting
The cutting part of the drivage cycle can be identified from the cutter motor
power and boom position. The cutter motor will be operating under load
conditions and the boom will move in such away that the cross-sectional area
of the roadway will be covered. Cutting may be interrupted with periods of
debris clearance, to enable identification of the current operation other services
which are in use during cutting and debris removal will be monitored, for
example water flow and apron position. The data for the cutter motor power
will be collected from either an 'intelligent' gate end box (ie Baldwin and
Francis DFS) or a Davis of Derby power transducer. Measurement of boom
position will either use existing optical encoders, similar to those used by the
ZEDminer profile control system, or cheaper high accuracy potentiometers.
An alternative boom position measurement system would use linear
displacement transducers incorporated in the boom arcing cylinders, (one in
each of the elevate and slew circuits). This type of monitored ram is soon to
be used as part of the face alignment control system, and experience with the
operation and reliability of these rams will indicate their suitability for mining
applications. The monitored ram may provide a method of retrofitting a boom
position measuring system on underground machines, but for the initial trial
an angular position sensor will be used.
The machine mounted monitoring system will then transmit the data on cutter
motor power and boom position to the surface, where the surface software will
determine from the cutter motor loading and movement of the boom within the
roadway when the cutting part of the drivage cycle is in operation.
4.2 Debris Clearance
Removal of the debris generated by the cutting operation is the next part of the
drivage cycle to be identified. It is very likely that this function will run
concurrently with the cutting operation, with the debris clearance equipment
operating during cutting.
The most common type of debris clearance system found on drivage machines
consists of an apron the width of the machine, fitted with two gathering arm
mechanisms. The gathering arms load the material onto a machine mounted
conveyor, which transfers the waste material to the rear of the machine and
onto the mine's material handling facility.
75
The gathering arm mechanisms are driven by hydraulic motors, the operation
of which can be detected from the hydraulic pressure in the supply circuit (see
figure 2). Measurement of the pressure either from a pressure switch or
transducer will provide the information to detect gathering arm operation.
Including accurate pressure and flow measurement would enable a more
detailed analysis of the circuit, such as detecting a burst hose, and diagnostic
data on relief valve settings but the extra cost of including pressure and flow
transducers in the circuit may not be justified for the addition benefits.
An alternative method of monitoring the gathering arm operation could be
achieved using a simple optical rotary device or rotary potentiometer fitted to
the drive shaft of the hydraulic motor. This type of sensor although cheaper
than a pressure transmitter will not provide any indication to the health of the
hydraulic circuit The sensor would also require some design work to engineer
the sensing device to the motor shaft. It is likely that in the future hydraulic
motors will be manufactured with position and speed transducers incorporated
into each unit, at minimal increase in cost, as automation within the hydraulics
field becomes more widespread.
Clearance conveyors fitted to roadway drivage machines can be either
hydraulically or electrically driven. Detecting the operation of the conveying
system will require data from either a power transducer or a hydraulic pressure
switch/transducer. As in the case of the gathering arm hydraulic circuit the use
of a pressure transducer in the circuit allows a more detailed analysis of the
circuit to be performed, enabling some diagnostic information to be presented,
such as conveyor stall due to overload or incorrect chain tension.
The monitoring trials will initially use pressure switches to determine the
operation of the debris clearance equipment but benefits from alternative
methods will be investigated.
4.3 Supports Set, Lagged and made Secure
Currently the setting and lagging of the roof supports is the manual part of the
drivage cycle. During the arch setting operation most of the machines services
will be stopped with only the power pack motor, boom, and tracks being in
operation. The drivage machine is used to assist in the lifting and placing of
the roof support, and for this purpose a arch lifting device is fitted to the
boom. The arch lifting device is commonly locked in a safe position at the rear
of the boom when cutting, and can only be moved forward for arch erection
with the use of an interlock key from the cutter motor power circuit.
By monitoring the position of the boom within the roadway and detecting
which services of the machine are operating will allow the support setting part
of the drivage cycle to be identified. On some roadway drivage machines,
monitoring the position of the arch lifting device with a micro switch fitted to
the mechanical Castel interlock, will indicate when support setting is in
operation.
76
With the introduction of roof bolting techniques, and bolting equipment

mounted to drivage machines. Detecting the roof support setting operation will
require the monitoring of the drilling rigs with suitable sensors. This will
enable the support setting procedure of these machines to be visible to the
monitoring system.
4.4 Machine Advancing
The advancement of the drivage machine along the roadway is the most
important parameter to be determined for drivage performance monitoring. The
actual process of determining accurately machine advance is more difficult
than the similar identification of shearer position. Shearers are restricted in
their direction of movement in so much as they only travel in reference to the
AFC and roof supports. Roadheading machines are unrestricted in their
movements, not being guided by chain or tracks, which could provide a
positive reference. This leaves the machine operator total flexibility in the
roadheader's movements. This freedom of movement makes computer
positioning of the machine within the roadway and along the drivage difficult.
Measurement of a drivage machine's advance rate must be referenced to the
start of the drivage or some known static point Determination using track
movement is not acceptable, as the tracks of the machine frequently slip during
the cutting and clearing operations, particularly in wet floor conditions.
Therefore the measurement of machine advance must be referenced to a static
and stable part of the roadway structure.
The use of a cord type transducer to measure the advance has been discounted
due to the vulnerability of the cord between machine and transducer. The
current cord transducers only measure the amount of cord which has been
withdrawn from the unit and have no facility to retract the cord when the
machine reverses, leaving loose cord to become damaged or broken. It is
envisaged that some form of noncontact measuring system would best satisfy
the requirements.
The introduction of new technology such as 'Laser Guide' currently under
assessment by British Coal, Research Division, will allow for performance
monitoring and guidance systems to share transducers. The 'Laser Guide"
system enables accurate positioning of the machine within the roadway,
enabling machine advance to be determined to an accuracy of 0.01m over
distances of 45-100m. Although the system allows accurate measurement, it
is expensive to be used solely as a machine advance measuring system. An
unknown factor for this measurement technique is the system's tolerance to
airborne dust and this is currently under investigation. This will prove the
system's ability to operate in an underground environment.
The successful development of the 'Laser Guide' profile guidance and
alignment system will provide an accurate method of machine advance and
boom position measurement but will require further work to integrate with
MACE.
77
The suitability of other methods of measuring machine advance are to be

investigated, for example the use of radar, ultrasonics, microwaves, and other
forms of optical measuring systems.
Determining the advance rate from the other drivage operations may be
possible, as they are cyclic in nature. This method of assessing the drivage rate
is not a precise measurement but during the circular tunnelling machine trial
at Cadley Hill it was possible to determine the number of supports set from the
data supplied from the other monitored parameters. Determination of the
drivage rate from the operation of other parts of the drivage cycle may be
acceptable in the majority of drivages, until a more accurate method is
available. With the increase in surface computer and software power,
identification of the the cutting and arch setting operations as discussed, will
allow the surface computer to ascertain the drivage rate in arches set or metres
advance.
4.5 Services Extended, Machine Serviced & Stoppages
Although the monitoring system will be designed to determine each part of the
drivage cycle, there will be times when the monitoring system will not be able
to identify the current operation. Such drivage functions as machine servicing,
conveyor extensions and stoppages will cause breaks in the data being
transmitted to the surface. The cause of the delay can be recorded at the
surface, but will require the manual input of data by the system operator.
4.6 Performance Monitoring Conclusions
The procedures outlined for performance monitoring will be tested to establish
the accuracy of the technique. The surface software will be configured to
analyse the data which will enable drivage performance to be presented in a
clear and concise format. In this mode MACE will be used as a performance
data aquisition and machine to surface transmission system but no performance
monitoring information available on the drivage machine.
5. Machine Health Monitoring
An ideal health monitoring system would predict and indicate impending failure of any part
of the drivage equipment. This however is impracticable and even if it was possible, the cost
of sensing all the required parameters would be prohibitive. (Table 1, gives an indication to
the extent health monitoring could be applied to a drivage machine). Discussions with colliery
and Technical department staff have taken place and it was generally agreed that monitoring
all services would generate large amounts of data, requiring excessive processing power.
Therefore, the parameters which directly influence the operation of the machine, and would
enable the operator to identify the cause of a machine stoppages, will be monitored initially.
Most of these parameters can either be monitored with existing transducers or by the adaption
of existing commercial transducers for underground use.
78
The important health monitoring areas are:1.
Measurement of Oil Levels
2.
Hydraulic Oil & Lubrication Contamination.
3.
Hydraulic Filter Condition.
4.
Hydraulic Power Pack and essential Hydraulic Services.
5.
Pressure & Flow of Water Cooling & Dust Suppression Circuit, both High
and Low Pressure.
6.
Electrical Supply.
7.
Cutter Motor operating Temperature.
5.1 Oil & Hydraulic Huid Levels

The measurement of oil levels for pilot circuit operation has been successfully applied
underground for a number of years. A low fluid level is detected by a float switch. For
better fluid management it is intended to provide a more accurate method of oil level
measurement.
Multilevel sensing transducers are now available from a number of manufacturers,
some which already supply to British Coal (TAV Ltd, Trolex). A magnetic float acts
upon reed switches mounted at different positions inside a nonmagnetic tube.
If the level of the fluid reaches a dangerous level for machine operation, the
monitoring system will respond with a visual alarm and message for the machine
operator and cause the machine to cutout. The alarm condition will also be recorded
and displayed at the surface console.
5.1.1 Hydraulic Oil Level Measurement
Measurement of hydraulic oil in the tank is seen as an important area of health
monitoring as damage to the hydraulic system is inevitable if the pump starts
drawing air and cavitation occurs.
The positioning of a level transducer within a hydraulic resevoir must be
considered during design as the operation of the the hydraulics will have an
effect on the oil level. This is due to surges in demand and the position of the
return lines causing surface fluctuations. Frothing of the hydraulic fluid is
another cause for erroneous level recordings but with correct design of float
and tube, this problem can be erradicated.
The use of a multilevel transducer will give an indication to the rate at which
the oil is being lost within the hydraulic system. However the system will be
unable to respond immediately to burst hoses due to the resolution of currently
79
available level transducers although overall loss of fluid will eventually be

detected.
5.1.2 Lubrication Oil Level Measurement
Semi-fluid greases are used extensively in gearboxes on drivage machines
which makes the quantity of lubricating material difficult to determine. The
two main oil filled gearboxes which would require constant level monitoring
are the power pack splitter box and the cutter motor gearbox.
The power pack splitter gearbox supplies the transfer from the power pack
motor to all the hydraulic pumps. The level of this gearbox oil will be
measured using a multilevel sensor. The monitoring system will be directed
only to measure the level of this gearbox when the power pack is not running.
The attitude of the boom and operation of the gearbox causes a problem in the
determination of oil level in cutter motor gearboxes. The monitoring system
will determine the level of fluid from a strategically placed multilevel
transducer reading and boom position measurement from the boom elevate
sensor.
5.2 Hydraulic Fluid and Oil Contamination
Contamination of lubricating and hydraulic oils has been recognized as an important
part of the colliery maintenance procedure. Over recent years most collieries have
benefited from the taking of regular oil samples from gearboxes on all types of
equipment.
To combat the problem in an on-line system Technical Department have developed
two transducers, one for ferrous debris measurement, and a water in oil sensor. These
are suitable for any pumped lubrication system with a flow rate of less than 5 1/min.
The operation of the debris sensor has been proved successful on shearer lubricating
systems, and it is intended to extend their use to drivage machines. To enable these
transducers to be used on the cutter motor gearbox an auxiliary pump will be required
as most roadheader boom gearboxes are splash lubricated.
Other on-line debris monitoring techniques are under development by Lindley
Flowtech and Trolex, The Lindley debris transducer operates on a back flush filter
principle and collects all debris particles, both metalic and nonmetalic over a set period
of time. Operational details of the Trolex device are at present unavailable. The
development of these transducers will continue to be monitored and their suitability
assessed when they become available.
As stated earlier, some gearboxes on roadheaders use semi-fluid greases for lubrication
which are of high viscosity, and standard debris monitoring techniques are unsuitable.
The investigation of debris analysis techniques for these materials is beyond the scope
of this project
5.3 Hydraulic Filter Condition Monitoring
80
Discussions with colliery staff highlighted that an indication of hydraulic filter

conditions before filter by-pass or blockage would be of great benefit. It was
considered important that the information should be available at both the drivage
machine, and the surface to enable the maintenance fitter to change the filter elements
at the next maintenance period.
A system manufactured by PALL for surface plant monitoring has been purchased for
trial and a design for an underground sensor, suitable for use on mobile plant is
currently being developed. With the availability of on-line sensing for filter blockage,
consideration is being given to the possibility of sensing wear within the hydraulic
system.
To obtain maximum benefit from full use of the filter monitoring package the
hydraulic circuit must be be a closed system, ie no access to the outside environment.
Using a pumped filling system through a filter, and a filtered breather unit will ensure
no external contamination will enter the system during filling or with the fluid level
changing. A possible source of contamination other than wear debris is paint and rust
from the inside of the hydraulic tank or when maintenance is carried out on the
hydraulic circuit. To stop paint and rust particles entering the system, manufacturers
are looking at different ways of coating the insides of hydraulic tanks or fabrication
from stainless steel.
5.4 Hydraulic Power pack and circuit monitoring
The hydraulic power pack is the heart of the drivage machine and for a drivage to be
successful it is important that the hydraulic power pack should operate reliably and
efficiently. Figure 3, shows the major components of a typical hydraulic power pack
supply and the necessary transducers to enable effective monitoring. Measurement of
the pressure, flow and fluid temperature will enable the efficiency of the power pack
to be determined when compared to the input power to the motor. Most power packs
have more than one power pack pump driven by the motor through a reduction
gearbox. The monitoring system will utilise the surface software power to analyse the
monitored data and identify any trend in the reduction of any of the pumps efficiency
during the machine's service.
Past research has shown that excessive negative pressure in the suction line can
generate cavitation of the pump leading to reduced efficiency and an increased wear
rate. The monitoring system will measure the suction Une pressure which is
proportional to the condition of the suction filters. Figure 4, shows a typical hydraulic
circuit found on a roadway drivage machine and the position of the sensors to allow
the service to be monitored effectively. The pressure and flow of all the individual
pumped supplies to the hydraulic circuits will be measured. This will allow main relief
valve settings and system operating pressures to be monitored continuously. The data
collected will also enable overall power pack efficiency to be calculated. Due to the
effects of fluid viscosity a temperature transducer/sensor will be required for accurate
flow calculation. Data from the temperature sensor in the hydraulic tank may be
acceptable, but this will be investigated. A pressure transducer in the pilot circuit will
provide an indication of operating and relief valve pressures.
81
5.5 Measurement of the Water Circuit

Recent efforts have been made by British Coal to standardise the water circuits on
roadway drivage machines. Figure 5, shows a typical water circuit for a roadheader
incorporating a high pressure water jet intensifier system for dust control and cutting
assistance, and air movers for methane dissipation. To ensure that statutory water
requirements are in operation the total flow to the circuit will be monitored.
Transducers positioned within the circuit will enable supply pressure, high water
pressure and air mover circuit relief valve pressure to be monitored.
5.6 Electrical Circuit Monitoring
Monitoring of the electrical input to roadheaders is currently carried out by MINOS
which takes the signals directly from 'intelligent' gate end boxes, and transmits the
information to the MINOS surface console. Due to the slow transmission speed of
MINOS the information available is limited. The power display allows the
determination of machine standing, idling or cutting. The faster transmission speed of
MACE will enable more information on power utilisation to be available. The MACE
unit mounted on the machine will allow power, voltage and current measurement to
be available to the underground personnel on request
Simultaneous monitoring of services which influence the pilot circuit i.e water circuit
pressure and flow, hydraulic oil level and temperature, will enable the drivage team
to be prewarned of any parameter that is about to enter a trip state. This will allow
them to take preventative action to ensure the drivage operation continues.
Time is frequently lost due to thermal cutout of the cutter motor, due to excessive
cutting load and insufficient cooling water. This halts the cutting operation until the
motor cools. Monitoring of the cutter motor temperature will enable the machine
operator to be given an indication of the impending thermal cutout in order to avoid
the situation. Incorporating a temperature transducer within the motor casing will
provide an operating temperature relative to the thermal trips.
An alternative method to determine thermal build up in the motor is the measurement
of the water cooling circuit. This method requires two temperature sensors but is the
easiest to retrofit to existing equipment. By installing temperature sensors in the supply
an exit lines of the cutter motor (See figure 5, Typical Water Circuit) an indication to
when thermal cutout will occur can be determined. The monitoring system will analyze
the temperatures and indicate to the machine operator that the motor is becoming
overheated.
Thermal cutout of the power pack motor is not normally a problem so long as cooling
water is supplied at a constant rate. The power pack motor is designed to operate
continuously supplying a constant pressure andflowfrom each pump. Operation of the
power pack motor with no cooling water will be detected from the monitored
parameters within the water circuit.
82
5.7 Health Monitoring Conclusion

Although health monitoring can be extended to all areas of the drivage machine the
parameters presented above represent the basis of a health monitoring package which
can be made available by using the standard MACE monitoring board. The standard
MACE monitoring board offers limited display and data processing facilities, giving
only textual indication of parameter states and alarm conditions. To enhance the
on-board displays and to allow data processing for future monitoring requirements,
such as a transducer communication data bus, an application board specific to
monitoring would need to be developed.
6. Surface Installation and Software
For the surface installation it is intended to interface with all current mining standards for data
manipulation and display. It is proposed to use a SCADA software package of the type
currently being reviewed by Monitoring and Control Branch as the replacement for SUMMIT.
SCADA is currently being configured to reproduce the displays as generated by SUMMIT
for the display of coal face information These types of information displays are well within
the scope of the package and it is expected that new applications will take advantage of the
software's capabilities.
SCADA software offers the possibility of monitoring of parameter trends which would help
to identify any reduction in the efficiency of the machine's services. This could enable
standard orifice tests to be recorded at the surface whilst being performed on the the machine.
The operator will be required to provide a manual input to the MACE module so that the
parameter under test can be identified by the surface. The SCADA system will record all
incoming data ready for analysis. Displays produced from the data will indicate deterioration
of each particular service tested and would be similar to the data currently retrieved manually.
The monitoring system will only be of benefit to the colliery if the information displayed is
useful and in a user-friendly format. Therefore it is expected that special attention will be
applied to specify and design informative displays that give a clear concise picture of the
drivage.
7. Programme
During 1991 it is intended to have the basis of a drivage monitoring system working on
underground trials at Middleton Mine. Figure 6, gives the programme of work form now until
project completion in March 1992. The parameters which will be monitored during the trial
are given in Table 2, which also identifies the transducers available commercially and those
which require further development work.
MACE will transmit data to a surface console, operating the SCADA software, which will
generate the displays for performance and health monitoring. This will enable the complete
system from transducers to surface installation to be developed and tested. An additional part
of the project is to investigate the use of 'intelligent' transducers that will operate on a
communications bus. This will reduce wiring, connections, and lead to a more detailed
analysis of the machine parameters at the signal source.
83
Figure 1. Drivage Cycle
84
To next
Hydraulic
Valve Bank
2 Press Switches
for BI -Directional
Services
F
Pilot Operated
Control Valve
Ps
Power Pack
Pumps
Filter
Port
Reliefs
3S
OO
Power Pack
Transducers
www
-Xii
GO"
Main Relief
Valve
(2300 psi)
Flow Divider
o
oo
UI
Gathering
Arm
Flow Trans
I Pilot Circuit
M
Relief Valve
(350 psi)
Pressure Trans
Ps
Pressure
Switch
Temperature Trans
Ps
.
X
Manual Operated
Control Valve
(Pilot)
Figure 2. Detecting the Operation of Hydraulic Circuits
Power
Transducer
-}-Po
.J
Filtered
Breather
__Frl
I .. I
Power
Pack
Motor
Hydraulic
Tank
Suction
Filter
00
Pv
To Hydraulic
Service
r~
Hydraulic
Pump
MultiLevel
Transducer
Flow
Transducer
Power
Po Output
Current
Output
Power Transducer
(Gate End Box or Davis of Derby Unit)
Voltage
Pressure
Transducer
V Output _
Temperature
Transducer
Vacuum
Pv Transducer
Figure 3.
Fc Filter
Condition Monitor
Power Pack Monitoring
Pressure
Line
Filter
To next
Hydraulic
Valve Bank
Hydraulic
Cylinder
Power Pack
Pumps
Filter
Fi4>
Pilot Operated
Control Valve
00=
Power Pack
Transducers
Ps
WWW
V \
JC3-
- E w X '
GO"
l p Main Relief
Valve
j (2300 psi)
Flow Divider
Ooo
vi
\-_
~\
F - Flow Trans
Pilot Circuit
J-J
Relief Valve
TJ
(350 psi)
Pressure Trans
Ps
Ps
Relief Valve
I (1000 psi)
Figure 4.
Pressure
Switch
Temperature Trans
Manual Operated
Control Valve
(Pilot)
iL
X
Foot Operated
Dead Mans
Pedal
^s:
Typical Roadheader Hydraulic Circuit
Dual
Filter
Pressure
Gauge
500 psi
Reducing
Valve
KN
ix-
600 psi
Relief
Valve
HXr0-20 GPM
Flowmeter
Hydrocyclone
Filter
Pressure
Gauge
0 - 5 GPM
Flowmeter
S top
Valves
JL
A
^
Oil Cooler
Fire Hose
Pressure
Transducer
oo
oo
Intensifier
Power Pack
Motor
Temperature
Transducer
-mCutter
Motor
Discharge Option
on to Conveyors
During Non-Cutting
Operations
Row
Transducer
-\r
-\r
Figure 5. Typical Roadheader Water Circuit
4ZE/
-o? r-
Manual
Diverter
Valve
Combined
i/omomea
Pressure/Flow
j
Switches
Air Movers
1990
I
y/AlSSOZ
ft
CO
1991
Xi
a*
1*4
1992
ft
Q)
CO
o
>
O
d
.J
Xi
&4
MONITORING OF ROADHEADERS REPORT
'/////
DEVELOP APPLICATION SPBCffiK! TRANSDUCERS
/////////////}
DESIGN ft ORDER TRANSDUCER FITTINGS FOR M/C

///////////ijSSSlOL
TRANSDUCERS ON ROADHEADER
'/////
INTEGRATE TRANSDUCERS AS AVAILABLE
*Lm
INVESTIGATE USE OF 'INTELLIGENT'
///////////////////
///////////////////////////7777/
ORDER MACE SUPPORT EQUIPMENT

~ y MACE FAMILIARISATION
'//.
U/G MACE UNIT AVAILABLE
00
' / / / / / / / /
mSTALL MACE ON ROADHEADER k COMMISSION
'////////////
V
///////A
TEST U/G MONITORING SYSTEM
ORDER U/GSURFACE TRANSMISSION EQUD?MENT

//////////
INSTALL TRANSMISSION EQUD7MENT
ORDER SURFACE MONITORING HARDWARE

V SPECIFY SURFACE INFORMATION REQUIREMENTS
STALL SURFACE HARDWARE AT TRIAL SITE
/ / / / / / /
INTEGRATE SURFACE WXTH U/G SYSTEM k COMMISSION
^^77777,
DEMONSTRATE COMPLETE MONITORING SYSTEM

MONITORING SYSTEM ELECTRICAL & LS APPROVAL
YZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZ
A
ECSC FINAL REPORT
Figure 6.
Y////////
Programme of Work
rzzzzzzzzzzzzzzzA
APPENDIX 2
Development of an 'Intelligent' Turbine Flow Transducer
Introduction
The incorporation of digital signal processing (DSP) techniques within transducers
enables many of the problems associated with analogue sensing elements to be
addressed at source. For instance normal sensor imperfections such as non-linearity,
drift, noise effects and frequency response can be minimised using DSP. The
development of low power signal chip microcomputers (SCM) allows for CPU and
memory to be incorporated into one integrated circuit. Incorporating such processors
into the transducer relieves the data acquisition system of a great deal of processing
function.
The Application of a SCM to a Turbine Flow Transducer for British Coal Mines
The 'on-line' measurement of hydraulic flow has been a problem for many years
within British Coal mines. Recent work on underground monitoring of Roadheading
machines highlighted the need for a flow transducer conforming to the British Standard
5754, (Specification for the electrical analogue and state signals for use within coal
mines). By using MACE (Multipurpose Automation and Control Equipment) as the
underground data acquisition system it is desirable that all inputs conform to BS5754,
and generate a voltage in the range of 0.4-2.0 volts proportional to the full scale
engineering unit being measured.
An assessment of available transducers and their suitability to accommodate the
requirements of underground monitoring lead to the choice of a turbine meter from
111 Barton Ltd. The meter suited the application as the unit was robust, with an
Intrinsically Safe (IS) pick-up and the internal components were easily exchanged if
damaged. Table A gives a brief specification of the requirements for a flow transducer
for use with the MACE monitoring system.
Health monitoring of a hydraulic circuit does not require a high degree of accuracy
from the flow transducer, since it is a reduction in volumetric flow rate from the
positive displacement pump examined over a period of time which is the desired
criteria. Therefore a slow sampling rate is quite acceptable, initially sampling once
every second, and averaging each new sample with the previous 4.
The conversion of the pulsed output generated by the turbine meter to a voltage output
in the range of 0.4-2.0 volts is easily achieved with the minimum of electrical
components using a SCM. Figure Fl shows the signal conditioning block diagram for
the first prototype circuit.
Microchip PIC16C55 SCM
The Microchip PIC16C5x series microcontrollers (Specification Sheet see Table B)
were chosen for the development of the flow transducer interface due to their low
power consumption and the cost of the PC based development package being relatively
cheap. A one day seminar was attended for product familiarisation. For the prototype
device the PIC16C55 (PIC55) microcontroller offering the most memory and I/O
terminals was chosen, but a it was found that the application software could be
accommodated within the memory of the PIC16C55 (PIC55).
93
Version 1 Flow Transducer Interface Circuit Design & Operation

Figure F2 shows the circuit design for the first prototype and corresponds to the block
diagram given in figure Fl. The electrical pulses generated by the turbine meter are
converted by the input op-amp into a 5v square wave, the pulses operate the clock
input to a 12 bit ripple counter. Two of the PIC55 outputs from Port A are used to
control the counter. The counter reset is operated directly from the PIC55, but the
input to the ripple counter is controlled via the AND gate to freeze the output during
a read operation. The data from the 12 bit counter is latched into the controller via
Port using another Port A output to select the lower 8 or upper 3 bits. (From the
turbine meter calibration data only 11 data bits required for a 1 second counting
period).
The data is then processed by the micro controller and the output sent to the D/A
convenor through Port C. The fourth I/O line from Port A being used to latch the
output in the D/A after a preset settling time. The output is buffered through a unity
gain op-amp.
After some examination of the circuit design it became apparent, that the prototype
circuit was too complicated, and that an easier solution was possible.
Version 2 Flow Transducer Interface Circuit Design, & Software Description
Circuit Description
It was noted that if the sampling time was reduced to ensure the pulse count was kept
below 255, the PIC's own internal counter could be used. A second circuit was
designed a block diagram showing the reduction complexity is shown in figure F3.
With the reduction in the number of inputs required to the PIC the new circuit
incorporated the PIC16C56 (PIC56) the largest memory version of the 18 pin chip,
with 12 I/O pins, the circuit used in the prototypes is given in Figure F4. The turbine
meter pick-up being connected across pins 3 & 4 of the upper 4 way header and the
power supply and signal output connected to the lower 4 way header.
The output from the flow transducer is conditioned into a 5v pulse train and is
directly connected to the Real Time Clock/Counter (RTCC) pin of the PIC56. The
operation of the counter being controlled through software. A dual op-amp is used for
both input and output signal conditioning. Port A is configured as output to control the
D/A control lines, and Port is used as the data transfer bus. The DAC used in the
circuit was chosen due to it's ability to directly interface with a microprocessor, and
the fact that it had an output of 0 - 2.55 volts referenced internally.
94
Software Algorithm
From the calibration graph for the 3/4" flow transducer the following equation was
derived:Gpm = 0.02926 * Hz - 0.12478
The initial transducer was designed to measure 0-20 Gpm with respect to the output
of 0.4-2.0 volts.
Frequency at 20 Gpm :f = (20+ 0.12478)/0.02926
f = 688 Hz
Calculate Resolution of DAC (ie f/bit)
DAC full range :- 0 - 255 bits
0 Gpm
20 Gpm
0.4 volts
2.0 volts
40 bits
200 bits
0 Hz
688 Hz
Hz/bit = 688 / (200 - 40)

Hz/bit = 4.3
Therefore to convert Hz to a voltage output proportional to Gpm, pulse count from a
1 second sample time must be divided by 4.3, and the result sent to the DAC.
As the PIC56 internal counter only has a maximum count of 255 the sample time must
be set at a value that ensures that this value is not exceeded. The flowrate used in this
calculation is the maximum flow the DAC can accommodate from its output of 2.55
volts.
Calculate Maximum measurable Range:DAC Full Scale = 160 + 55 bits
DAC FS = 215 bits
Therefore:Maximum Frequency = 4.3 * 215 = 925 Hz
Maximum Flowrate = (0.02926* 925) -0.12478 = 26.94 Gpm
To ensure a reasonable amount of over-range capacity, to accommodate other sizes of
95
turbine meter and to simplify the mathematics a sample time of 0.2 seconds was
chosen.
On power up the system is initialised by configuring the I/O ports and setting the DAC
output to 0.4 volts. All the data registers are initially cleared and the DAC is allowed
to settle before latching.
On entry to the main part of the program loop the watchdog timer and RTCC
configuration is updated to ensure constant refreshing of the option register. The new
count data is multiplied by 5 to give a count value for 1 second.
The 1 sec value is then added to the last 5 recorded 1 second values to provide a small
amount of signal smoothing. A test is then carried out to see if the total of the last 5
values are greater than 5, if not the program assumes the flow is zero. If the value of
the last 5, 1 second counts are greater than 5 then the value is divided by 5 and the
integer part being used as the new 1 sec value.
The value to be sent to the DAC is calculated next, to simplify the mathematics and
remove a division of 4.3 the new 1 sec data is first multiplied by 10, and then divided
by 43. This value now represents theflowrateand after the 0 offset of 40 is added the
value is sent to the DAC.
After the DAC has received the new data and been latched on, the latest reading is and
the 3 preceding that are switched in the registers to clear the new data register for the
next value.
The RTCC register is then read exactly 0.2 seconds after it was last cleared and the
count stored in the new data register.
The RTCC is cleared and the loop starts again for the next data value. For accurate
flow measurement the timing of the loop is critical and must be kept to 0.2 second
from counter start to counter stop, regardless of which route the program takes. To
ensure correct timing a number of subroutine 'wait' calls are made and a few No
Operations (NOP) are utilised.
List 1, gives a full listing of the flow transducer software for the PIC16C56, and a hst
of the processor instruction set and compiler extended instruction set.
Transducer Software and Hardware Testing
The software was compiled initially in a form so that it could be tested on the PIC
simulator program on a PC. The PICSIM software is provided as part of the PIC
development package. The simulator allows one step program control and enables the
user to check file register contents and timing details, before an actual chip is
programmed. After a few minor problems with timing details the software was
operated successfully on the simulator, and then transferred to a EPROM version of
the PIC16C56, ready for hardware testing.
Two prototype transducers were made 1 for measuring 0 - 2 0 Gpm and the other to
96
measure 0 - 3 2 Gpm. Figure F5 shows the transducer and the interface PCB. Both
units were mounted on a roadway drivage machine the 20 Gpm unit in the water
circuit and the 32 Gpm unit in a hydraulic supply circuit. Both operated successfully
during the period of the trial and although a full calibration was not possible at the
time, but by referencing them to other types of underground flow measuring equipment
appeared to give satisfactory results.
Conclusions and Recommendations
The two units were internally power by 9v battery, but on an LS version some form
of external power supply would be required. Due to the relatively large current (15mA)
required by the circuit only a limited number could be directly powered from the
MACE unit. Therefore for a large number of flow transducers to be used on the
monitoring system an alternative supply would require associated barrier circuits to be
incorporated into the transducer circuit design. Or alternatively a lower operating
current circuit could possibly be designed.
The current circuit must also be modified to allow for some input offset adjustment
on the output Op-Amp as this was found to affect the output voltage from the DAC.
The use of a single dual 8-pin op-amp in the circuit was probably a mistake and two
separate op-amps for the input and output should be used in future to allow voltage
offset to be accommodated. In the prototypes the circuit was built and lab tested to
determine the effect of the voltage offset and then adjusted within the software for
each unit by either increasing or decreasing the 40 bits added to the result.
A new PIC microprocessor is expected to be released shortly, which will include an
ADC pin, this could be used to monitor the output form the transducer and software
could internally compensate for the any irregular effects of the circuit, ie Temperature
compensation and Op-amp offset.
The work on the flow transducer interface gives a base to build upon and could ensure
a that the problem of reliable flow measurement in British Coal mines is eventually
surmounted.
97
5V PULSE
___--
SCHMITT
TRIGGER
PULSE
CONTROL
12 BIT
COUNTER
(AND GATE)
(4040)
12
PIC16C55
TURBINE METER
PICK-UP
IO
IO
DAC
8 BIT
(AD557JN)
OP-AMP
(7612)
UNITY GAIN
Figure Fl. Block Diagram for 1st Prototype Circuit
0 . 4 - 2 . 0 VOLTS
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I n t e l l i g e n t Flow Traneducep C i r c u i t Design A

Size [Document Number
N.D.Jenkinson
July ae. 199a Sheet
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OP-AMP
5V PULSE
jruruism
PIC16C56
(7612)
SCHMITT
TRIGGER
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PICK-UP
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CONTROL
DAC
8 BIT
(AD557JN)
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(7612)
0.4-2.0 VOLTS
o
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UNITY GAIN
Figure F3. Block Diagram for 2nd Prototype Circuit
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FLOW TRAN I/F
TYPE: TSRE/NDJ/VO/1
Size Document Number
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Figure F5. Prototype 'Intelligent' Flow Transducer
103
Table . PIC Microcontroller Specification Sheet
PIC16C5X
Microchip
EPROM-Based 8-Bit CMOS Microcontroller Series

FEATURES
Low power, high speed CMOS EPROM technology
Wide variety of EPROM and RAM sizes, oscillator
types, frequency ranges and I/O configurations
Fully static chip design
Operating Frequency Range:
- DC - 8 MHz (20 MHz future release)
Operating voltage range:
- Standard: 4.0V to 5.5V
- Low power: 3.0V to 5.5V
Low power consumption:
- <2mA ( 4 MHz, 5V, XTAL oscillator)
- 15 typical (32 KHz, 3V, XTAL oscillator)
- < 3 standby typical (3V, O'C to 70'C)
Available in temperature ranges:
- Commercial = O'C to +70'C
- industrial
=-40'C to+85"C
Wide selection of 18 and 28 lead packaging
options: PDIP, SOIC, PLCC, or CERDIP Window.
Also available in die form.
512 to 2048 words of 12-bit program EPROM

32 to 80 words of 8-bit data RAM
Only 33 single 12-bit word instructions to learn
8-bit ALU
12 or 20 bidirectional l/O's with individual direction
control
2 level stack for subroutine nesting
Direct, indirect, immediate, and relative addressing
modes for data and instructions
8-bit real time clock/counter (RTCC) with selectable
signal source and trigger edge
Free running on-chip watchdog timer
8-bit prescaler, assignable to RTCC or watchdog
timer
Oscillator start up timer
Power on Reset
Security EPROM fuse for code protection
QTP (factory programming) available
FIGURE 1 PIN CONFIGURA TIONS

PDIP, SOIC
CERDIP Window
PDIP, SOIC
CERDIP Window
>RTCC C
VOD C
<>RA2
44 RA 3
RTCC
>MCLR
Vss
RB0
RB1
<>R82
4RB3
PLCC
17
16
PIC
15
16CS4
16CS6
14
13
12
11
10
R R
C
6 5
N/C
Vss
N/C
RAO
<>RA1
-RA2
<-RA3
<-RB0
<-R81
<-RB2
<-RB3
<-RB4
RA1 <>
RAO <>
OSC1
OSC2/CLKOUT
VoD<
RB7 <
RB6
RB5 <
RB4
C
C
C
C
C
C
C
C
C
C
C
C
PLCC
R R
8
2 1
18 17 16 15 14 13 12
RB7 C 19
RB0
RC1 U 19
N/C
N/C
RC2 C 20
N/C
N/C
RC3 C 21
Vss
RC4 c 22
N/C
7 VSS
RCS C 23
N/C
6 3 N/C
RC6 C 24
5 3 N/C
RC7 C 2S
PIC16C54
PIC16CS6
voo
OSC2
26
U
S
C
1
27
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1
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14
13
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9 3 RA3
PIC16C55
PIC16C57
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7 D RA1
6 3 RAO
26
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s
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5 3 N/C
Table A
Flow Transducer Specification

General Description
The flowmeter is to be used as part of a Routine Condition &
Performance monitoring package on roadway drivage machines and
coal face equipment.
The unit will be mounted on the machine and should be capable
of withstanding severe vibration without affecting accuracy.
Due to the limit space available on coal cutting machinery
the size of the unit should be kept to a minimum, including any
flow straighteners which may be necessary.
The unit cost is also a consideration.
Ideally all sigmal conditioning will be performed within the
transducer unit. The output from the transducer should be a
voltage linear to flow rate in the range of 0.4 - 2.0 volts. The
transducer should be Intrinsically Safe (I.S), and conform to B.S
5754, (Electrical analogue and state signals for use in coal
mines).
No flow indication is required at the sensing unit all signal
processing and display is remote.
Specification
Flowrate
Operating Pressure
Accuracy
0 - 55
0 - 150
0 - 200
1% Full
1/m
1/m
bar
Scale
(0 - 12 gal/min)
(0 - 30 gal/min)
(0 - 3000 psi)
Electrical Requirements : Flowmeter to be Intrinsically Safe and satisfy HSE requirements

for use in British coal mines.
Voltage Input 12v unregulated or lOv regulated.
Voltage output 0.4-2.0v full scale.
Mechanical Requirements : Fluid Type:- 60/40, 95/5 invert emulsion or mine water.
Fluid Spec:- 60/40 invert emulsion Aquecent Heavy.
(Century Oils)
Kinematic Viscosity (Cst)
IP 71
@ 25C - 193
@ 40C 91 Operating
0
Temperature
@ 50C 61
@ 60C -41.5
Specific Gravity
@ 16C 0.958
Prefered Material:316 stainless steel
No light metal alloys or non-approved plastics.
105
Listing 1
T Y P E RTCC Clock
INTELLIGENT FLOW TRANSDUCER 0.4-2.0V OUTPUT
Designed By N.DJenkinson BSc(Hons) C.Eng MIMinE
This Interface is designed to allow the connection of
Turbine Type Row Transducers to a MACE Module with
a Voltage output range of 0.4-2.0v. and comply
with BS5754.
Software Version 3.1
Tested & Modified 29 August 1992
This is a new version of flow transducer software

for the RTCC Type 'B' Design.
Setup Parameters for the Assembler

org
00
include
ACCaHi
ACCaLo
ACCbHi
ACCbLo
ACCcHi
ACCcLo
ACCc3
ACCdHi
ACCdLo
NDatHi
NDatLo
AvDtffi
AvDtLo
DatlHi
DatlLo
Dat2Hi
Dat2Lo
Dat3Hi
equ
equ
equ
equ
equ
equ
equ
equ
equ
equ
c:îc\picsii
09
0a
Ob
0c
Od
Oe
equ
010
011
equ
013
equ
015
equ
equ
equ
equ
equ
Of
012
014
016
017
018
019
01a
109
Dat3Lo
Dat4Hi
Dat4Lo
temp
equ
equ
equ
equ
Ole
Olb
Ole
Old
Initialise
SUBROUTINES
include c:îc\picsim\flow\wait.asm
Wait asm is a software programmable time wasting routine which
when used with NOPs can enable timing loops to
be programmed to the nearest microsecond to be used.
Minimum time available using waitasm, 22uS.
c :\pic\picsim\flow\Dbl_add. asm
include
Dbl_add.asm is a standard double precision adding routine

as supplied by Microchip.
c :Npic\picsim\flow\NDJ1 DIV.asm
include
NDJ16DIV.asm is the standard double precision division

routine supplied by Microchip which has been modified to
ensure that the routine takes the same number of clock
cycles irrespective of the numerator and denominator.
main
movlw
option
clrw
tris
tris
movlw
movwf
movlw
movwf
clrf
clrf
clrf
clrf
clrf
clrf
028
PAO
PA2
; Set Port A to Outputs

; Set Port to Outputs
028
PA2 ; Set DAC Outp
06
PAO ; Enable DAC
FSR
DatlHi
Dati Lo
Dat2Hi
Dat2Lo
Dat3Hi
; Use Settling
110
clrf
clrf
clrf
clrf
clrf
movlw
movwf
clrf
clrf
movlw
movwf
call
clrf
Dat3Lo
Dat4Hi
Dat4Lo
NDatHi
NDatLo
OE
; Latch DAC to 0.4 Volts
PAO
ACCcLo
ACCc3
00
; Set for Wait Time
ACCcH
WATT ; Let Transducer Settle Wait X lOths of a Second
RTCC
L
Start Main Transducer Algorithm
START
clrf
movlw
option
fsr
028
Multiply New Data by 5 to give 1 Second Value

movfw
movwf
movfw
movwf
clrf
clrf
call
call
call
call
call
movfw
movwf
movfw
movwf
NDatHi
ACCaHi
NDatLo
ACCaLo
ACCbHI
ACCbLo
D_add
D_.add
D..add
D_add
D..add
ACCbHi
NDatHi
ACCbLo
NDatLo
>C SJC 3fC3ft
movfw
movwf
movfw
movwf
movfw
movwf
NDatHi
ACCaHi
NDatLo
ACCaLo
DatlHi
ACCbHi
111
; Add Last Five Counts for Average
Dati Lo
ACCbLo
movfw
movwf
call
movfw
movwf
movfw
movwf
call
movfw
movwf
movfw
movwf
call
movfw
movwf
movfw
movwf
call
D _addi
Dat2Hi
ACCaHi
Dat2Lo
ACCaLo
D._add
Dat3Hi
ACCaHi
DaLo
ACCaLo
D..add
Dat4Hi
ACCaHi
Dat4Lo
ACCaLo
D..add
Test Average Data > 5
ACCbHI
BigNum
06
TSTF
BNZ
movlw
CLRC
subwf
be
goto
BigNum
Over5
nop
nop
ACCbLO.w
Over5
Less5
nop
nop
nop
nop
Calculate Average of the Last Five Readings
movlw
movwf
clrf
call
movfw
movwf
05
ACCaLo
ACCaHi
D_divF
ACCbHi
AvDtHi
112
movfw
movwf
ACCbLo
AvDtLo
Calculate the Data for Output to DAC

AvDtHi
ACCdHi
AvDtLo
movfw
movwf
movfw
clrc
rlf
rlf
clrc
rlf
rlf
clrc
rlf
rlf
clrc
addwf
skpnc
incf
clrc
addwf
skpnc
incf
movfw
addwf
addwf
AvDtHi
ACCdHi
AvDtHi
AvDtHi
movfw
movwf
movfw
movwf
movlw
movwf
clrf
clrf
clrf
call
AvDtHi
;Divide 10 * Average 1
ACCbHi
AvDtLo
ACCbLo
02b
ACCaLo
ACCaHi
ACCcHi
ACCcLo
D_divF
; ACCbHi & Lo Holds Result
; Multiply Avei
AvDtLo,f
AvDtHi,f
AvDtLo,f
AvDtHi,f
AvDtLo,f
AvDtHi,f
AvDtLo,f
AvDtHi
AvDtLo,f
Add Offset for 0.4 Volts to Value for output to DAC

movlw
movwf
clrf
call
goto
028
; 40 Decimal to Add
ACCaLo
ACCaHi
D_add ; DAC Output in ACCbLo, ACCbHi should be 0
DACout
113
Waste Time if Data Totals were < 5

sic sk sii st? sk sk sk sic efesie sie sk sic sic slesk sic sii sic sic sic sic sic sic sic sic sie sic sic sic sic sie sic sic sic sie sie sic sic sie sie ite sic ile ile ile ile sic ile sic sic sic sic sic sic sic sic sic slcslcsfe sie sie sie sie
Less5
movlw
movwf
movlw
movwf
clrf
caU
nop
nop
nop
nop
nop
09f
; Set for Wait Time to Catch Up with BigNum
ACCcLo
00
ACCcffi
ACCc3
wait
nriTi
nu
movlw
movwf
28
ACCbLo
Output ACCbLo Value To DAC & Latch Output
DACout
movfw
movwf
movlw
movwf
nop
nop
nop
nop
nop
nop
nop
nop
nop
movlw
movwf
ACCbLo
; Move Data to Output Port
PA2
01
; Enable DAC to Read I nputs
PAO
; Settling Time for DAC to get Input Data
09
PAO
; Latch DAC at Data Value
Switch Data
movfw
movwf
movfw
movwf
movfw
Dat2Hi
DatlHi
Dat2Lo
Dati Lo
DaHi
114
Dat2Hi
Dat3Lo
Dat2Lo
Dat4Hi
Dat3Hi
Dat4Lo
Dat3Lo
NDatHi
Dat4Hi
NDatLo
Dat4Lo
movwf
movfw
movwf
movfw
movwf
movfw
movwf
movfw
movwf
movfw
movwf
; Data Switched
Waste Time to Time Period = .2 secs

movlw
movwf
movlw
movwf
movlw
movwf
call
Ode
; Set for Wait Time to Catch Up with BigNum
ACCcLo
080
ACCcHi
00
ACCc3
wait
Get New Data from RTCC File (f 1)
movfw
clrf
movwf
clrf
goto
RTCC
RTCC
NDatLo
NDatHi
START
;NDATHi always ZERO
org
PIC56
LIST p=16c56
goto Entry
END
sie sie sie sic sic sie sic sie ile sieste sie sie sie ile sie sic sic ite sie sie sie sie sie sie sie sie ile niesle sie sie sie sie sie sie sie sie sie sie sie sie sksle sie sie sie sie sie sie sie sie sie sie sie sie st* sl st* sic st* sie sie sie
115
PIC16C5X Series
INSTRUCTION SET SUMMA RY
BYTE ORIENTED FILE REGISTER OPERA TIONS
(11-6)
(5
(4 -0)
OPCODE
f(FILE#)
d = 0 for destination W
d = 1 for destination f
Instruction-Binary (Hex)
Name
Mnemonic, Operands
Operation
Status Affected
Notes
0000 0000 0000
000
No Operation
NOP
None
0000 001 f ffff
02f
Move W to f
W->f
None
0000 0100 0000
040
Clear W
MOVWF f
CLRW
0-W
0000 011f ffff
06f
Clear f
CLRF
0-*f
0000 lOdf ffff
08f
Subtract W from f
SUBWF
f, d
f - W - d [ f + W + 1-d]
C, DC,
1,2,4
0000 11df ffff

0001 OOdf ffff
OCf
Decrement f
DECF
f, d
f-1 _>d
2,4
lOf
14f
Inclusive OR W and f
I0RWF
f, d
Wvf->d
2,4
AND Wand f
ANDWF
f, d
W&f->d
2,4
0001 10df ffff
18f
Exclusive OR W and f
XORWF
f, d
WS f->d
2,4
0001 11df ffff
1Cf
Add Wand f
ADDWF
f, d
W + f->d
C, DC,
1,2,4
0001 01 df ffff
1,4
4
0010 OOdf ffff
20f
Move f
MOVF
f, d
f-d
2,4
0010 01 df ffff
24f
Complement f
COMF
f, d
f-d
2,4
INCF
0010 10df ffff
281
Increment f
2,4
2Cf
Decrement f.Skip if Zero
f, d
DECFSZ f, d
f + 1 ->d
0010 11df ffff
f -1 - d, skip if zero
None
2,4
0011 OOdf ffff
30f
Rotate right f
RRF
f, d
f(n)-d(n-1),C->d(7),f(0) ->C
2,4
0011 01 df ffff
34f
Rotate left f
RLF
f, d
f(n)->d(n+1),C->d(0),f(7) ->C
2,4
0011 10df ffff
38f
Swap halves f
SWAPF
f, d
f(0-3) <-> f(4-7) -> d
None
2,4
0011 11df ffff
3Cf
Increment f.Skip if zero
INCFSZ
f, d
f + 1 - d, skip if zero
None
2,4
instruction-Binary
BCF f , b
(He )
0->f(b)
0101 bbbf ffff
5bf
Name
Mnemonic,Operands
None
2,4
BSF
0110 bbbf ffff
6bf
Bit Set f
Bit Test f.Skip if Clear
0111 bbbf ffff
7bf
Bit Test f, Skip if Set
OPCODE
Name
b(BIT #)
Operation
None
BTFSC
->f(b)
Test bit (b) in file (f): Skip if clear
BTFSS
f, b
Test bit (b) in file (f): Skip if sel
None
Mnemonic.Operands
f(FILE #)
Status affected
f, b
f, b
LITERAL A ND CONTROL OPERA TIONS
Instruction-Binary (Hex)
(4- O)
(7-5
(11-8)
BIT ORIENTED FILE REGISTER OPERA TIONS
2,4
None
(11-8)
(7-0 )
OPCODE
k (LITERA L)
Operation
Status affected
0000 0000 0010
002
Load OPTION register
OPTION .
W -> OPTION register
None
0000 0000 0011
003
SLEEP
0 -4 WDT, stop oscillator
TO.PD
0000 0000 0100
004
Go into standby mode

Clear Watchdog timer
0000 0000 Offf
OOf
CLRWDT -
Tristate port f
TRIS
TO.PD
0 > WDT (and prescaler, if ssigned)
as
None
W-> I/O control register f
1000 kkkk kkkk
8kk
Return.place Literal in W
RETLW
k -> W, Stack -> PC
None
1001 kkkk kkkk
9kk
Call subroutine
CALL
PC + 1 - Stack, k -> PC
None
101k kkkk kkkk
Akk
Go To address (k is 9 bit)
GOTO
k
k
None
1100 kkkk kkkk
Ckk
Move Literal to W
MOVLW
k -> PC (9 bits)
k->W
None
1101 kkkk kkkk
Dkk
Incl. OR Literal and W
kvW->W
1110 kkkk kkkk
Ekk
AND Literal and W
IORLW
ANDLW
k&W->W
1111 kkkk kkkk
Fkk
Excl. OR Literal and W
XORLW
kW->W
117
Notes
Notes
3
1
SUPPLEMENTAL
INSTRUCTION
SET
SUMM A RY
The following supplemental instructions summarized

below represent specific applications of the basic PIC
instructions. For example, the "CLEAR CARRY" suppiemental instruction is equivalent to the basic instruc-
tion BCF 3,0 ("Bit Clear, Re 3, Bit 0"). These instruction

mnemonics are recognized by the PIC Cross Assemblg
A
(PIC L),
Name
Instruction-Binary
Mnemonic,
Equivalent
Status
Operands
Operation(s)
Affected
010
000
. 000
011
Clear Carty
CLFC
BCF 3.0
010
100
000
011
Set Carry
SETC
BSF3.0
010
000
100
011
Clear Digit Cany
CLRDC
BCF 3,1
010
100
100
011
Set Digit Cany
SETC
BSF3.1
010
001
000
011
Clear Zero
CLFIZ
BCF 3,2
010
101
000
011
Set Zero
SETZ
BSF3.2
011
100
000
011
Skip on Carry
SKPC
BTFSS3.0
011
000
000
011
Skip on No Cany
SKPNC
BTFSC 3, 0
011
100
100
011
Skip on Digit Carry
SKPDC
BTFSS3.1
011
000
100
011
Skip on No Digit Carry
SKPNDC
BTFSC 3,1
011
101
000
011
Skip on Zero
SKPZ
BTFSS 3, 2
011
001
000
011
Skip on No Zero
SKPNZ
BTFSC 3. 2
001
000
Iff
fff
Test File
TSTFf
MOVF f, 1
001
000
Off
fff
Move Hie to W
MOVFW f
MOVF f. 0
001
001
001
010
Iff
dff
fff
fff
Negate Rie
NEGFf.d
COMFf. 1
INCF f. d
011
001
000
010
000
dff
011
fff
Add Carry to Rie
ADDCF f, d
BTFSC 3, 0
INCF f. d
011
001
000
011
000
dff
011
fff
Subtract Cany from Rie
BTFSC 3,0
DECFf.d
011
001
000
010
100
dff
011
fff
Add Digit Carry to Rie
BTFSG3.1
INCF f, d
011
000
000
011
100
dff
011
fff
Subtract Digit Carry from Rie
BTFSC 3.1
DECFf.d
101
kkk
kkk
kkk
Branch
B k
GOTO k
011
101
000
kkk
000
kkk
011
kkk
Branch on Carry
BCk
BTFSC 3.0
GOTO k
011
101
100
kkk
000
kkk
011
kkk
Branch on No Carry
BNC k
BTFSS 3.0
GOTO k
011
101
100
kkk
100
kkk
011
kkk
Branch on Digit Carry
BDC k
BTFSC 3.1
GOTO k
011
101
001
kkk
000
kkk
011
kkk
Branch on No Digit Carry
BNDC k
BTFSS 3,1
GOTO k
011
101
101
kkk
000
kkk
011
kkk
Branch on Zero
BZk
BTFSC 3.2
GOTO k
011
101
101
kkk
000
kkk
011
kkk
Branch on No Zero
BNZk
BTFSS 3, 2
GOTO k
118
SUBCF f, d
ADDDCFf.d
SUBDCFf.d
APPENDIX 3
BRITISHCOALCORPORATION
TECHNICAL SERVICES AND RESEARCH EXECUTIVE
INTEGRATED SYSTEMS BRANCH
DRAFT BRITISH COAL SPECIFICATION

APPLICATIONS PROTOCOL
Application Sheet for Monitoring of Roadheaders using MACE.
PROTOCOL
7.3
APPLICATION
07o
STATUS
01
VERSION
1.2
Author:
N.D.Jenkinson
Date:
13th February 1992
Issue 1
File Ref:
This document is confidential and is the copyright of The British Coal Corporation. It may not be
reproduced or communicated in any way, in whole or in part, without their express permission.
Cautionary Note
This specification is issued to enable supervised monitoring trials on a roadheading machine to be
conducted.
Changes may be made as a result of experience gained.
Prior to any implementation of the contents, the revision status should be checked.
Any queries should be directed to British Coal Corporation, Technical Department.
121
INTRODUCTION
This document contains the application sheets for the roadheader application of MACE (Multi-purpose
Automatic control Equipment). A separate application sheet is defined for each MACE board as they
are individually designated a unique slave address, ie communications, monitoring and applications.
These sheets should be read in conjunction with the British Coal Specification for Application Protocol,
draft 7.3, which defines how data, if available, is to be transmitted. Further extensions to the
applications protocol have been necessary to achieve the desired data transmission features. These
extensions have now been formally agreed.
These sheets have been designed with reference to previous sheets dealing with the Natural Gamma
Radiation steering application of MACE on power loading machines (application 06o version 01), and
the applications sheet for powered supports (application 05o version 1.4).
2
SCOPE
These sheets identify the specific use for guidance and monitoring of roadheaders of the specification
for applications protocol (and conforms to draft 7.3 of the above specification).
This specification defines the requirements for guidance and monitoring of boom type roadheaders only.
The document will be amended at a later date to include other types of machine.
This is the first version of sheets for the roadheader application and will be issued prior to any
exhaustive trials with the MACE system. The status of the issue is "experimental" and further additions
will be made as a result of practical trials and with further system developments.
3
HISTORY
This specification is based on the Draft British Coal Specification for Applications Protocol.
4
DATA REQUIREMENTS FOR MACE
The main features of data transmission between MACE on a roadheader and the surface facilities are
summarised below.
4.1
Data to be transmitted to the surface.

The data to be transmitted from the MACE installation/node to the surface station (DEXTERITY)
will be as follows:-
4.1.1
Power-up message (specifying the generation time underground of power-up, the underground
time of the previous power-down and a MACE module internal power-up status).
4.1.2
Module initialisation message (request, on first power-up, for commissioning data for the MACE
applications board.
4.1.3
Event message (transmitted on the occurrence of an event oron the subsequent power-up after
a power loss due to a detected error condition) - defines noteworthy occurrences and faults.
4.1.4
Commissioning and parameter changes (performed by means of the MACE keypad, or from the
surface.
4.1.5
Request from the surface for specific data.
4.1.6
Other protocol dependent criteria, eg change of 10x resolution.

123
4.2
Parameters to be transmitted underground

The data to be transmitted from the surface station (DEXTERITY) to the MACE module will be
as follows:-
4.2.1
Request for data (eg time default basis, parameter verification or operator request).
4.2.2
Underground event log access (future development).
4.3
Commissioning Data Master

The applications protocol is adopted with the surface end (DEXTERITY) assuming "master" role
on the data link.
It is essential that the MACE monitoring system must be fully operational even when the data
link is down. Therefor the commissioning parameters (and, eventually the configuration data)
stored in the MACE module, ie the machine characteristics, must always be assumed to be the
valid version (the current working version). The machine assumes the possession of the master
version of the commissioning parameters.
Adequate security is to be provided to prevent unauthorised access both at the surface and
underground.
The hierarchy of control is to be defined as follows:-
4.3.1
With the data link healthy, any change initiated underground will be transmitted to the surface
and the surface file(s) updated.
4.3.2
With the data link healthy, any change initiated at the surface will be transmitted underground
and the reply to the change, after it has been stored in MACE, will initiate that value being
stored at the surface.
Note that items 4.3.1 and 4.3.2 imply high integrity data transmission between machine and
surface installation.
4.3.3
With the data link not healthy or the surface down, any changes initiated underground will be
stored in MACE. On the subsequent link re-initialisation, the surface must request the current
MACE commissioning parameters and perform a check. Any differences will be logged as such.
The current and previous commissioning and configuration values are to be available for
inspection at the surface. The previous values, identified by time, are to be saved for short term
reference.
It may be necessary to enhance the integrity of the data link by demanding checks at the MACE
and the surface station on transmission of commissioning values.
The automatic updating of commissioning values is essential.
124
APPLICATIONS DATA UNITS
Number bases will be identified by the following suffixes:

H
o
Hexadecimal
Octal
Binary
Numbers with ho suffix will be decimal. All other abbreviations are specified in the Specification for
Applications Protocol.
The following table gives a list of application data units for the roadheader application of MACE.
ADU Type
Indication
Transaction error
Data Set
System Data
Time Stamp
State Data (1)
Family of Analogue Data Type (1)
Plant Fault
Application Dependent
Current )
Next
)
Previous
) Event log access
Select
)
Events
)
Configuration Data
Full Identification
SXNNo
Start up Notify
(see note below)
OOo
01o
05o
06o
07o
10o
22o
24o
30o
1
1
2
41 o
42o
43o
44o
45o
50o
NOTE.
1.
Always sent following MACE Module power-up initialisation.
2.
Sent if a fault is present when the MACE modem is initialised.
ADU's which are not described in the following section (marked * in the table above) are as described
in the Specification for Application Protocol.
For ADU's which concern options not implemented by a particular unit, the transaction error (SXN 01o)
will be sent in reply to a request.
5.1
Identification
The identification ADU is identified by SXN - OOo.

The Data Segment in the Notify and Reply ADU's from the MACE module will contain a two byte
identification code as follows:125
byte 1 :
bits O - 5
bits 7,6
byte 2:
01
07o
Roadheading Machine
Experimental
bits 0 - 3
MACE board type
bits 4 - 6
General equipment type
MACE board type

000
Unspecified
01 o
Communications Board
02o
Roadheader Monitoring Board
04o
Roadheader Application board
General equipment type
OOo
06o
07o
Unspecified equipment
Boom roadheader
Continuous miner
Note that each MACE board has a unique slave number.

5.2
Data Set
The Data Set (or association) ADU is identified by SXN - 05o.

The Data Set ADU is used to group together ADU's where a consistent or related set of data is being
transmitted. All ADU's following the start of Data Set will be considered to be part of the same set of
related data form a given MACE board or application, until the end or termination of the association is
determined.
The Data Set will have three byte qualifiers defined as follows:Byte 1
Byte 2
Byte 3
Sequence number from source.

Block number.
Number of blocks in association.
For this ADU only, bits 6 and 7 of the SXN are to be used to define the message type (ie request, reply
or notify).
It is essential for the MACE application to guarantee that certain message types are successfully
received for logging (eg Events and possibly certain groups of control and condition monitoring data)
bearing in mind the possible frequency of power on/off sequences.
All these messages will be held within the Data Set and may occupy more than one ADF. The MACE
application will demand a reply from the surface by specifying a type Request Data Set message. This
will be achieved within the existing protocol by setting the transaction type bits of the Data Set ADU
as required.
The start of a Data Set in an ADF is identified in a block number = 1. Subsequent ADF's of the current
Data Set will be headed with the Data Set ADU and the continuation is defined by a block number >
1. If the Data Set is of type Request, the continuation of Data Set ADU will also be designated a type
Request.
The surface will respond with a transaction type Reply Data Set ADU;
(This is not yet finalised) - covered by time stamping?
The associated message is either retransmitted or deleted from the transmit queue.
126
Note that no nesting of Data Sets from the same board or slave is allowed. The only restriction on the
use of the Data Set ADU is that the total inclusive message length must not exceed 1024 bytes.
Note that it is unlikely that Data Set will be used in initial roadheader applications which are concerned
with monitoring only.
5.3
System Data
The System Data ADU is identified by SXN - 06o.

The time and date will be transmitted to MACE as a broadcast (logical address 00H) upon receipt of
a data link Initialisation ADU (SXN OOo).
The time and date will be conveyed by two separate System Data ADU transmissions qualified by a
first byte identifier. The Time Broadcast will be as follows:-
5.4
Data Type
Data Value
01H Time
byte 2: hours (0 - 23)

byte 3: minutes (0 - 59)
byte 4: seconds (0 - 59)
02H Date
byte 2: day (1 - 7, 1 = monday

byte 3: day of month (1 - 31)
byte 4: month (1-12)
byte 5: year (last 2 digits)
Time Stamp
The Time Stamp ADU is identified by SXN - 07o.

Where the exact timing or sequence of timings of a reading, or a group of readings is required, the
Time Stamp ADU is to be used.
The Time Stamp ADU is an 8 byte value in numerical time format. The Time Stamp ADU will be used
to identify the source time at which a message or group of readings, or other data was generated
(underground MACE time) and will permit analysis of the roadheader performance and condition data.
It is however unlikely that Time Stamp will be used in initial applications as the monitoring is not time
critical.
The format of the Time Stamp ADU is as follows:byte 1: month (1-12)
byte 2: year (0 - 99)
byte 3: hours (1 - 23)
byte 4: day (1-31)
byte 5: seconds (0 - 59)
byte 6: minutes (0 - 59)
byte 7: low byte milliseconds ) (0 - 999)
byte 8: high byte milliseconds)
The MACE Module will be frequently initialised due to the roadheader being powered up and down
during its normal operations. The Time Stamp ADU contains the absolute time of day which requires
to be reset on initialisation of the roadheader module. This is achieved by exchanging the System Data
ADU (SXN 06o).
127
Note
The MACE calendar clock is a true four word "absolute" time, and therefor, the byte pairs are reversed
when considering the consecutive memory locations containing that time value.
5.5
State Data (1)
The State Data ADU is identified by SXN - 10o.

This is as specified in the Specification for Applications Protocol and is of a mask format with up to 64
digital channels.
5.6
The Family of Analogue Data Type (1) ADU is identified by SXN - 22o.
This ADU is used to transfer 8 bit analogue data in grouped families of data, either derived values or
from transducers required by that MACE board (or application) on the roadheader.
5.6.1 Table Definition
The application data tables will consist of two table number bytes and two mask bytes followed by a
maximum of 16 analogue values. Each analogue value, or channel, defines a 2 byte field containing
that channel's status byte and the analogue data byte respectively.
This ADU has been allocated a maximum of 8 tables, (ie 19 bytes max excluding a Time Stamp and
other headers)
The transmission criteria are to be specified for all the tables employed.
5.6.2
Analogue Status Byte
The analogue status byte is as described in the Specification for Application Protocol and has the
following qualifiers:a)
After the transducer has been flagged over or under range, the relevant bit(s) shall be held at
OB until the transducer remains in range for one minute ( or other specified period). During this
time, changes in analogue data values shall be notified in the normal manner.
b)
Alarm state bits shall be used to reflect local alarm conditions where possible (and logically
feasible) as this will always generate a transmission. Once set, the alarm state should be held
at OB until the alarm condition has cleared for one minute (or other specified period) before
being resetto 1B.
5.7
The Family of Analogue Data Type (2) ADU is identified by SXN - 24o. This ADU is used to transfer
16 bit analogue data in grouped families of data, either derived values or from transducers required by
that MACE board (or application) on the roadheader.
5.7.1
Table Definition
The application of data tables will consist of two table number bytes and two mask bytes followed by
a maximum of 16 analogue values. Each analogue value, or channel, defines a 3 byte field containing
the channels status byte and the 2 analogue data bytes (low and high) respectively.
Note that each analogue value represents a signed integer quantity with negative numbers in 2's
complement format.
128
This ADU has been allocated a maximum of 32 tables.

The transmission criteria are to be specified for all tables employed.
5.7.2
Analogue Status Byte
The analogue status byte is as described in the Specification for Application Protocol and has the
following qualifiers:a)
After the transducer has been flagged over or under range, the relevant bit(s) shall be held at
OB untilthe transducer remains in range for one minute (or other specified period). During this
time, changes in analogue data values shall be notified in the normal manner.
b)
Alarm state bits shall be used to reflect local alarm conditions where possible (and logically
feasible) as this will always generate a transmission. Once set, the alarm state should be held
at OB until the alarm condition has cleared for one minute (or other specified period) before
being reset to 1B.
5.8
Plant Faults
The Plant Fault ADU is identified by SXN - 30o.

For the MACE application, the Plant Fault ADU is to be used to convey the MACE event. Within the
definition of the Plant Fault ADU (SXN - 30o), optional extra bytes can be specified up to a defined
maximum.
This ADU is as described in the Specification for Application Protocol with the following qualification of
the Notify Data Segmentbyte 2
byte 3
byte 4
byte 5
byte 6
byte 7
:
:
:
:
:
byte 87 :
number of extra bytes (nominally 4)

alarm priority.
Event number (low byte)
Event number (high byte)
reminder interval
)
) text up to a maximum of 80 characters
)
Alarm priority (for surface processing)

00H
01H
02H
03H
No alarm required (default)

Low alarm
Normal alarm
High alarm
Reminder interval (for repeat of Event)

01H
02H
03H
04H
05H
06H
No reminder (default)
Power up
Power up, Specified times (eg shift change)
Power up, every hour
Power up, every 30 minutes
Power up, every 10 minutes
(The use of alarms is to be defined on roadheaders)

Note that for the display of alarm messages, the maximum text length must not exceed 70 characters
otherwise the Time Stamp will overwrite part of the text string, it is assumed that an interfacing routine
129
will allocate the necessary default attributes at the surface to correctly specify the Event for the alarm
handling routines (ie operator knowledge required, line printer, etc). See Design Specification for
Common Alarm Handler Package for further details.
An Event will be transmitted on every occurrence (ie application dependent). A qualifier bit may be
defined within the Application identifier to provide a return-in-range type Event should a unique Event
number be unavailable. An Event message will not exceed 128 bytes in total.
5.9
Application Dependent
A total of five ADU's have been allocated for the MACE application and these are to be used initially
for the internal MACE communications. Eventually, the Event Log within the MACE module will be
accessible using these ADU's via the external data link.
5.9.1
Current
The Current ADU is identified by SXN - 41 o.

5.9.2
Next
The Next ADU is identified by SXN - 42o.

5.9.3
Previous
The Previous ADU is identified by SXN - 43o.

5.9.4
Select
The Select ADU is identified by SXN - 44o.

5.9.5
Events
The Events ADU is identified by SXN - 45o.

5.10
Full Identification
The Full Identification ADU is identified by SXN - 50o.

This ADU is to be transmitted on every power up of the MACE Module and is used to ensure system
compatibility.
An additional flag will be used to indicate the first power up of the MACE Module and this could be
used in the future for down load of commissioning parameters.
This ADU is as described in the Specification for Application Protocol with the following additional
qualif cations :byte 1
byte 2
byte 3
byte 4
byte 5
byte 6
byte 7
Application sheet version No.

Manufacturer's code.
Manufacturer's type No.
Manufacturer's firmware release No.
Configuration revision level.
Number of extra bytes (1).
First power up flag.
00H - no action
01H - commissioning request
The configuration revision level for underground or locally configurable applications should be
130
incremented whenever a configuration change is undertaken.

6
CONFIGURATION
The area of configuration (for the MACE Monitoring Board only) requires to be sorted out.
Configuration is required to define a channel text descriptive, range high and low limits, conversion to
an engineering unit and information regarding signal processing (ie signal averaging, frequency of
sampling, etc).
7
BROADCAST INFORMATION
There are no specific application broadcast messages for the roadheader application.
8
PRIORITY
All messages will be designated "high" priority.

9.
TIMEOUT AND LINK FAILURE
The individual boards in MACE (ie Communications, Monitoring and Applications will be designated to
act as a slave to the master (the surface) on the transmission network.
The MACE Module will timeout if the reply interval expires before the receipt of an acknowledgement.
The initial reply interval will be 5 seconds based on the poll technique adopted, the half duplex design
of the link, the transmission rate of 9.8 kbits/sec and that a maximum of only 128 bytes of data can be
transmitted per message.
The heartbeat will be transmitted every 8 seconds from the master to maintain the link and re-initialise
the link as necessary. Further details are available from Automation Technology Branch.
Should the data link be broken, the MACE Module is designed to operate as a stand alone unit and,
hence, all applications will remain operational. Any configuration and /or commissioning changes must
be notified when the link is re-established.
Adequate care must be exercised when the link is lost (eg power down of the roadheader system) such
that the Data Set or association is suitably terminated or handled. In general, the MACE messages not
fully transmitted and acknowledged will be re-transmitted.
10
TYPICAL MACE MESSAGE CONSTRUCTION
The following messages are required for an underground trial to provide suitable surface information
for performance assessment and fault analysis. They are wholly constructed from the defined ADU's
in the Specification for Applications Protocol, draft 7.3 issue 2, and the additions contained within this
Application Sheet.
All messages are to be logged by the "Dexterity" system on the surface, excepting those pertaining to
the Application Protocol (eg transmission of all data values after the power up sequence has occurred
to ensure all the defined "Dexterity" channels are initialised. Each MACE Board will perform this task
as each one is designated a slave role.
All transmissions requiring the use of the Data Set (or association) ADU (SXN - 05o) are to be
inclusively limited to 1024 bytes in length. It is important that the messages are received at the surface
in the correct chronological order.
Currently all MACE transmissions are Notify or Reply types with the exception of the Data Set ADU
which are Notify or Request type.
131
All data messages will contain a Time Stamp of the trigger event and will, therefor, be conveyed within
the Data Set or association ADU's
10.1
MACE Power-Up Message

The power-up message from a MACE Board (ie Communications, Monitoring or Applications)
will have the following formalIdentification (SXN - OOo)
link initialisation
Full Identification (SXN - 50o)
first power-up flag
Data Set (SXN - 05o)

Time Stamp (SXN - 07o)
Plant Fault (SXN - 30o) :
START
power-off Event
underground power-off time
START
power-on Event
underground power-up time

Plant Fault (SXN - 30o)
The Identification and Full Identification ADU's are always of transaction type Notify. The power-off and
power-on Events may be of type Request (note that "Dexterity" treats the MACE as one plant item and
it may not be necessary to log all MACE board power-on and power-off Events).
10.2
MACE Event Message

The MACE Event message will have the following formatData Set (SXN - 05o)
START
Plant Fault (SXN - 30o) :
Event No and/or text
underground generation time
In general, all MACE Events will be of type Request ( to ensure that the surface has received the
message correctly for logging).
The Event may be further qualified by sending related data values ( to enable more precise fault
analysis at the surface) as appended additional text to the Event description.
It may be necessary to link Events or faults to data values at the surface. This would be achieved by
ensuring that the Event and Data message source times are identical.
Care must be taken to limit the total length of the text description.
132
10.3
MACE Data Logging Message
The MACE logging and Commissioning data message formats (tables of values) are defined in the
appendices together with their specified transmit criteria.
Application and health data may be of either transaction type Request or Notify.
The message has the following general formatData Set (SXN - 05o)
Analogue Data type (1) 8 bit
Table Number(s)
Mask Bytes
Channel Data
Channel Data
Table Number(s)
Mask Bytes
Channel Data
Channel Data
Table Number(s)
Mask Bytes
Channel Data
Channel Data
Table number(s)
Mask Bytes
Channel Data
Channel Data
START (size of association)

data values
CONTINUATION
data values
The majority of the Roadheader application data transmission for initial monitoring applications will be
transmitted on change of monitored values or alternatively, triggered by time interval.
133
Data and Controls Type Legends

The data definitions are described in terms of Analogue Data Types (8 and 16 bit) and Analogue
Control Types (8 and 16 bit) as in the Applications Protocol. These specifications will be extended as
the development requires and are not to be considered complete.
The legends used in the Applications Sheets are as follows:GE
CW
ACW
FSp
m
mm
min
s
deg
mV
pu
Gate End
Clockwise
Anti-clockwise
Full speed
Metre
Millimetre
Minute
Second
Degrees
Millivolts
Pulse
Denotes an item which can be derived at surface ie choice of engineering unit
available for MACE.
135
APPENDIX A
MACE COMMUNICATIONS BOARD
The data to be transmitted from the communications board (apart from its normal message bus
received data transmit function) will consist of diagnostic data from the HDLC - Message Bus interface
software and possibly certain Events. This has yet to be specified.
Link diagnostic will be accommodated outside this document.
137
APPENDIX
MACE MONITORING BOARD
The Monitoring Board will perform the most Roadheader health monitoring and initially is independent
of any Application Board functions.
139
MACE MONITORING BOARD

B.1
TRANSMIT CRITERIA
The monitoring data will be transmitted on the following criteria:a) On change of state defining an Event or clearing.
b) On failure of a transducer.
c) Following initialisation of the external data link.
d) At a fixed frequency.
e) In reply to a request for data.
The trigger for sending data will be:a) Time based.
b) Change of status.
Where multiple changes need to be transmitted, the Data Set ADU will be used to associate such data.
The Time Stamp will be included with every transmission from the Monitoring Board.
141
B.2
FAMILY OF ANALOGUE DATATYPE (1)
j_
SXN 22o
This ADU is used to transmit 8 bit analogue data to the surface, the data table will consist of a table
number byte, 2 mask bytes and a maximum of 16 analogue values
For each of these analogue values there are 2 associated bytes. The 2 byte sequence for each channel
gives the status byte followed by the 1 byte analogue value ie 19 bytes maximum excluding Time
Stamp and other necessary headers.
The analogue status byte is as described in the main specification for Applications Protocol.
143
FAMILY OF ANALOGUE DATA TYPE (1)

B.2.1
SXN 22o
Hearth Data - Table 1

Anderson Strathclyde RH1/4 Roadheader
Item
Channel
Boom cutter gearbox (B/C)

Gathering arm gearbox (G/A)
Conveyor drive gearbox (C/D)
Track drive gearbox (T/D)
Parameter
Resolution
Signature Count
8.192V Reference (mon

board)
0 - not healthy
1 - healthy
0-63
A2
Tank Fluid Level
0 - Low
1 - normal
2 - High
3 - Indeterminate
N/A
Oil level B/C gearbox
0 - low
1 - normal
2 - high
3 - Indeterminate
N/A
Oil level C/D gearbox
0 - low
1 - normal
2 - high
3 - Indeterminate
N/A
Oil Condition C/D

gearbox
0 - contaminated
1 - normal
N/A
Oil level power pack

gearbox
0 - low
1 - normal
2 - high
3 - Indeterminate
8
9
10
11
12
13
14
15
16
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
.
"
145

B.2.2
j_
SXN 22o
Health Data - Table 2.
Anderson Strathclyde RH1/4 Roadheader. Hydraulic system
Item
Channel
Parameter
D13
Caterpillar Track
LH forward
0 - no drive
1 - drive
D14
Caterpillar Track
RH forward
0 - no drive
1 - drive
D15
Caterpillar Track
LH backward
0 - no drive
1 - drive
D16
Caterpillar Track
RH backward
0 - no drive
1 - drive
D11
Pressure switch apron

lift
0 - lower
1 -lift
D10
Pressure switch apron

sump
0 - sump out
1 - sump in
Resolution
D7
Pressure switch G/A

motor LH
0 - no drive
1 - drive
D8
Pressure switch G/A

motor Rh
0 - no drive
1 - drive
D17
Pressure filter No 1
0 - clear
1 - blocked
10
D18
0 - clear
1 - blocked
11
D19
0 - clear
1 - blocked
Continued....
146

B.2.2
j_
SXN 22o
Hearth Data - Table 2. - Continued....
Anderson Strathclyde RH1/4 Roadheader. Hydraulic system
Item
Channel
Parameter
12
D20
Pressure Filter No 4
0 - clear
1 - blocked
13
D21
Pressure Filter No 5
0 - clear
1 - blocked
14
D22
Return Filter No 1
0 - clear
1 - blocked
15
D9
Pressure Switch Bridge

Conveyor Motor
0-Off
1 - Running
16
D12
Pressure Switch Rear

Jacks
0 - up
1 - down
147
Resolution
B.3 FAMILY OF ANALOGUE DATA TYPE (2)

B.3.1
Hearth Data - Table 1.
Anderson Strathclyde RH1/4 Roadheader.
Item
SXN 24o
Channel
Boom Position
Cutter Motor
Conveyor Motor
Parameter
Resolution
Signature Count
0-63
8.192V Reference mon

board
2mV
A4
Boom Elevation
2mV
A3
Boom Slew
2mV
A5
Boom Sump Depth
2mV
A37
Cutter Motor
Power
2mV
A36
Cutter Motor Voltage
2mV
A25
Cutter Motor
Temperature
2mV
A34
2mV
10
A33
Water Circuit Flow
2mV
11
A39
Electric Conveyor Motor

Power
2mV
12
A40
Conveyor Hydraulic
Motor Pressure
2mV
13
A41
Conveyor Hydraulic
Motor Flow
2mV
14
N/A
Oil Temperature B/C

Gearbox
2mV
15
16
Undefined
Undefined
"
148

B.3.2
j_
SXN 24o
Anderson Strathclyde RH1/4 Roadheader. Hydraulic System.
Item
Channel
A38
Parameter
Power Pack Motor Power
Resolution
2mV
Power Pack Motor Temp

2mV
N/A
A16
Hydraulic pump No 1
Pressure
2mV
A17
Hydraulic Pump No 2
Pressure
2mV
A18
Hydraulic Pump No 3
Pressure
2mV
A30
Hydraulic Pump No 1
Flow
2mV
A31
Hydraulic Pump No 2
Flow
2mV
A32
Hydraulic Pump No 3
Flow
2mV
A21
Hydraulic Pump No 1
Suction Pressure
2mV
10
A22
Hydraulic Pump No 2
Suction Pressure
2mV
11
A23
Hydraulic Pump N
o 3 Suction
Pressure
2mV
A26
Hydraulic Pump No 1
Supply Temperature
2mV
13
A27
Hydraulic Pump No 2
Supply Temperature
2mV
14
A28
Hydraulic Pump No 3
Supply Temperature
2mV
12
15
16
Undefined
Undefined
'
149

B.3.3
j_
SXN240
Anderson Strathclyde RH 1/4 Roadheader. Hydraulic System.
Item
Channel
A24
2mV
A29
Hydraulic Tank
Temperature
2 mv
A40
Not Used
Yet
Chain Conveyor
Pressure
2mV
A41
Not Used
Yet
Chain Conveyor Flow
2mV
5
6
7
8
9
10
11
12
13
14
15
16
Parameter
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
Undefined
150
Resolution
APPENDIX 4
INTEGRATED SYSTEMS BRANCH

Pilot Core Data Transmission Tests
N.DJenkinson
14 July 1992
1.
Introduction
1.1 Test Procedure
2.
Wallacetown A67 Gate End Box
3.
Wallacetown A74 Gate End Box
4.
5.
3.1
A74
POIS Out
3.2
A74
POIS In
POIS Out
Wallacetown SIMOS Gate End Box

4.1
SIMOS
POIS Out
4.2
SIMOS
POIS In
Baldwin & Francis FT/M11A Gate End Box

5.1
P130
POIS Out
5.2
BZ1
POIS In
6.
Baldwin & Francis BFS Gate End Box
7.
Conclusions
153
1. Introduction
The following tests were carried out to establish if the data communication system incorporating the
latest MACE modems and the 'E' series repeater, would operate successfully on type 7 trailing cable.
The data being transmitted along the trailing cable pilot core, superimposed on the pilot signal. The test
equipment was set up as shown in Figure A, in the MACE shearer test lab at TSRE. Tests were to be
carried out on all types of pilot circuit currently in use within British Coal mines. To ensure all pilot circuit
designs were covered 5 gate end boxes were made available. These were:)
ii)
iii)
V)
A67
'A74
SIMOS
BZ1
BFS
If the gate end box was operational with POIS (Prevention Of Inadvertent Start) in circuit the test
procedure was followed for each mode of operation, conventional and POIS. POIS ensures that before
the machine is allowed to start the 30 ohm resistor is switched in circuit within 4 seconds after a
request to start.
An identical test procedure was followed for each pilot circuit, the test procedure designed to identify
any interference between the operation of the pilot circuit and the data communication link. During each
test various pilot and data signals were recorded on a digital storage oscilloscope and a hard printed
copy made.
1.1 Test Procedure
i)
With machine stood and ruggedised modem out, Check and record pilot signal.
ii)
Start machine, Check and record pilot signal.
iii)
Stop machine.
v)
Insert ruggedised modem, Check and record pilot signal.
v)
Start machine, Does machine start? Check and record pilot signal.
vi)
Stop machine, Does machine stop?
vii)
Start transmission, Check and record pilot signal
viii)
Start machine, Does machine start? Check and record pilot signal.
ix)
Stop machine, Does machine stop? Check and record pilot signal.
x)
With machine stood, Record signal at Test Point 14' on repeater and machine modem.
xi)
With machine running, Record signal at Test Point 14' on repeater and machine
modem.
xii)
With machine stood, Record signal at Test Point 8" on repeater modem.
xiii)
With machine running, Record signal at Test Point 8" on repeater modem.
xiv)
Check operation of transmission system during 20 start/stops of machine.
155
TREND
DATA SOURCE
RX/TX
RS232-MACE
COMMS
CONVERTOR
-vi
\ MACHINE
PILOT CIRCUIT
G.E.B
UNDER
TEST
'E'
BOX
REPEATER
MODEM
SURFACE
LINK
MACE SURFACE
INTERFACE
FIGURE A. TEST EQUIPMENT CONFIGURATION
TREND
DATA SOURCE
RX/TX
Test Point 14:- Test point after isolation transformer on Modem.

Test Point 8:-
Test point after filtering, prior to FSK chip on Modem.
2. Wallacetown A67 Gate End Box

The A67 is the oldest design of gate end box out of the 5 tested. The pilot circuit conforms to the British
Coal Specification P130. The traces recorded of the pilot and data signals are given in Figures 67a
67m.
ft
IV AC
lQms/DIV
500raV OFF
Trig=AJ
I
ft
P/P =
3.20
V
FREQ:
50.
Hz
I
1
-
il
"
IV A C
lQms/OIV
1
'1
P/-P:
2.08
V
FREQ:
50.
Hz
|
,*--r\
B500mV0FF
Trig:AJ
1
,_
mfg-
Sy _
- ^ \
fr
HM * * \ -
'%
*.
1
RUN
RUN
SPECIAL FUNCT=
Figure 67a. Pilot Signal, Ruggedised Modem Out

of Circuit, Machine Stood.
SPECIAL FUNCT:
Figure 67b. Pilot Signal, Ruggedised Modem Out

of Circuit, Machine Running.
158
ft IV AC
lOms/DIV
B500mVOFF
Trig:AJ
A
IV AC
10ms/DIV
<
B5O0mVOFF
Trig:AJ
I
I
I
,
P/P2.16
V
FREQ:
50.0
Hz
'| m
RUN
SPECIAL FUNCT:
SPECIAL FUNCT
Figure 67d. Pilot Circuit Signal, Ruggedised

Modem in Circuit, No Data Transmission,
Machine Running.
Figure 67c. Pilot Circuit Signal, Ruggedised

Modem In Circuit, No Data Transmission,
Machine Stood.
A IV AC
lras/DIV
5O0mV OFF
Trig:AJ
1
1
A IV DC
10ms/DIV
B50GmVOFF
Trig:AJ
1
1
1
1
~~\
"
'
/:
2.24
V
FREQ:
50.0
Hz
*-
RUN
SPECIAL FUNCT:
SPECIAL FUNCT
Figure 67e. Pilot Circuit

Transmission, Machine Stood.
1 V
1
1
1
Signal,
Data
Figure 67f. Pilot Circuit Signal,

Transmission, Machine Running. (1v/Div)
159
Data
A500mVDC
lOms/DIV
B500mV0FF
Trig=AJ
P/P'
2.24
V
FREQ:
50.0
Hz
1
1
-
T"
il
fC
SJ
i**H
U
SPECIAL FUNCT'
RUN
Figure 67g. Pilot Circuit Signal, Data

Transmission, Machine Running, (500mV/Div)
AlOmV DC
ljjs/DIV
B500mV0FF
Trig:AJ
A lOOmV DC
10JS/DIV
P/P'
384
mV
FREQ'
65.8
kHz

1 11 / \
'
'
fi
L
J' /
B 5O0mV OFF
Trig:AT
1
1
iv! \
VI', i *
"
V xl'' \
SPECIAL FUNCT:
RUN
1
SPECIAL FUNCT
Figure 67h. Data Signal Test Point 14,

Ruggedised Modem, Machine Stood.
Figure 67. Data Signal Test point

Ruggedised Modem, Machine Running.
160
14,
A lOmV DC
ljjs/DIV
1
B500mVOFF
Trig:A/
I
I
I
,
/356
mV
FREQ'
69.4
kHz
A' A A
7 V i \ I\
"
r/ \~i~ \~~
r~
P/P356
mV
FREQ:
78.1
kHz
fsAr A r A
"
RUN
~\T ~ \J'~ ~
1
1
1
1
1
RUN
SPECIAL FUNCT:
Figure 67j. Data Signal Test Point 14, Repeater

Modem, Machine Stood.
A lmV DC
lOys/DIV
7 11 / 1 \
/ V / l J l
SPECIAL FUNCT:
I \ j \
|
1
1
1
1
500mV OFF
Trig:AJ
AlmV DC
lys/DIV
<
Figure 67k. Data Signal Test Point 14, Repeater

Modem, Machine Running.
AlmVDC
lOus/DIV
;
1
500mV OFF
Trig:AJ
P/P:
144
mV
FREQ:
78.1
kHz
B500mV0FF
A
Trig= J
1
1
1 ~~
' rrn
j Lu_ LX LL L I _LJ_ L
P/P:
140
mV
FREQ'
78.1
kHz
^rLL
LLLLLi
I
'
"
RUN
Figure 671. Data Signal Test Point 8, Repeater

Modem.machine stood.
RUN
SPECIAL FUNCT'
SPECIAL FUNCT:
Figure 67m. Data Signal Test Point 8, Repeater

During the test no problems were encountered with starting or stopping the machine, and data
transmission over the pilot core was not affected by running the machine. From traces figure 67a/b, and
figures 67c/d it is apparent that insertion of the ruggedised modem in the pilot circuit has no significant
effect on pilot operation. From the other traces it is apparent that no detrimental effect on the pilot
circuit is observed whilst transmitting data, and that no data corruption occurs form pilot circuit
operation.. During the start/stop tests data errors were detected 6 times by the Trend' at the machine
end. No errors were recorded in the data at anytime on the surface Trend'. The transmission was
stopped during start up on 3 occasions, with the machine running no problems were encountered in
re-establishing the communication link.
161
Attempts were made to test the A67 gate end box with POIS in operation but due to technical reasons
the machine would not start when operated in this mode. It was therefore decided not to test the POIS
mode of operation for the A67.
3. Wallacetown A74 Gate End Box
The Wallacetown A74 gate end box is one of the most common types used within British Coal. The box
tested was a double outlet type and configured such that one outlet was operational with POIS, and
the other outlet with POIS out of circuit.
3.1 Wallacetown A74 POIS Out of Circuit
With the machine power from the A74 gate end box with POIS out of circuit the test procedure was
observed and the following oscilloscope traces recorded. Figures 74a-74m show the pilot and data
signals observed during the test.
During the test no problems were encountered in starting or stopping the machine, and no interference
between pilot signal and data transmission was apparent. From studying the traces recorded no
detrimental effects were observed either to the pilot signal or the data transmission during the test, and
the inclusion of the modem in the pilot circuit caused no obvious deterioration of the pilot circuit
function, Figures 74a/b & 74c/d. During the start/stop tests the data transmission system stopped
communicating 4 times during start up, and errors in the data were identified during 6 starts at the
machine end. Restarting the communication link after a transmission failure was not a problem.
A IV DC
10ms/DIV
200mV OFF
Trig
1
"
!
!
!
SPECIAL FUNCT'
A IV DC
lms/DIV
P/P<
2.16
V
FREQ'
50.0
Hz
RUN
Figure 74a. Pilot Signal, Ruggedised Modem Out

of Circuit, Machine Stood.
200mV OFF
Trig'AT
;
!
:
:
:
:
1
SPECIAL FUNCT:
'
!
P/P =
1.44
V
FREQ'
50.0
Hz
RUN
Figure 74b. Pilot Signal, Ruggedised Modem Out

of Circuit, Machine Running.
162
A
IV DC
10ms/DIV
200mV OFF
A
Trig' J
I
,
"
\\J
\ j
"
P/P:
2.16
V
FREQ
50.0
Hz
!
;
!
;
t \ \
A
IV DC
lms/DIV
"
W
;
; RUN
!
RUN
SPECIAL FUNCT:
Figure 74c Pilot Circuit Signal, Ruggedised

Machine Stood.
A
IV DC
10ms/DIV
B200mVOFF
Trig:AJ
I
I
I
,
1
1
-
Figure 74d. Pilot Circuit Signal, Ruggedised

Machine Running.
A IV DC
10ms/DIV
P/P:
2.28
V
FREQ'
50.0
Hz
1
4
B2O0mVOFF
A
Trig: J
1
1
1
1
1
:
P/P'
1.48
FREQ:
50.0
Hz
1
1
RUN
"
SPECIAL FUNCT:
Figure 74e. Pilot Circuit

1
1
1
"
1-
'L/ L
P/P:
1.44
V
FREQ:
50.0
Hz
AAAA
\ j '\ j
SPECIAL FUNCT'
B200mV0FF
A
Trig: J
1
1
RUN
SPECIAL FUNCT:
Signal,
Data
Figure 74f. Pilot Circuit Signal,

163
Data
A500mVDC
lms/DIV
'
Zp\~
B200mVOFF
Trig'AJ
I
I
I
,
'
1Â~
p/p=
1.60
V
FREQ'
50.0
Hz
m
RUN
SPECIAL FUNCT:
Figure 74g. Pilot Circuit Signal, Data

A 100mV DC
ljjs/DIV
1
B500mV0FF
Trig'AJ
1
^tfyAA /i
l\'\t'
AlOmV DC
lys/DIV
BSmVOFF
Trig'ftJ
P/P'
396
mV
FREQ'
75.8
kHz
'1 III
\}\
3H9H
SPECIAL FUNCT'
Figure 74h. Data Signal Test Point 14,

SPECIftL FUNCT'
Figure 741. Data Signal Test point

164
14,
lOmV DC
lOus/DIV
1
. . L
'
B500mV0FF
Trig'AJ
1
AlmV DC
lys/DIV
/ / 17
500mV OFF
Trig:AJ
P/P'
308
mV
FREQ'
75.8
kHz
a/J L \i \
-
"
1
1.
1
1
1
1
HOLD
SPECIAL FUNCT'
SPECIAL FUNCT'
Figure 74j. Data Signal Test Point 14, Repeater

ft 100mV DC
10WS/DIV
~~.
~i
500mV OFF
Trig:ftJ
1
1
Figure 74k. Data Signal Test Point 14, Repeater

AlOOmVDC
lOjJs/DIV
P/P'
144
mV
FREQ
75.8
kHz
FlfMJ
500mV OFF
Trig'AJ
1
P/P:
144
mV
FREQ:
78.1
kHz
FlififLMk
-
RUN
SPECIAL FUNCT:
Figure 741. Data Signal Test Point 8, Repeater

Modem,machine stood.
I
RUN
SPECIAL FUNCT:
Figure 74m. Data Signal Test Point 8, Repeater

165
3.2 Wallacetown A74 Gate End Box with POIS in Operation

With the machine power from the A74 gate end box with POIS in operation the test procedure was
observed and the following oscilloscope traces recorded. Figures 74Pa-74Pm show the pilot and data
signals observed during the test.
function, Figures 74Pa/b & 74Pc/d. During the start/stop tests the data transmission system stopped
communicating once on start up, and registered errors in the data, identified during one start at the
machine end. Restarting the communication link after a transmission failure was not a problem.
A IV DC
10ms/DIV
1
1
1
1
1
B20OmVOFF
Trig'AJ
1
1
1
R-- - -
P/P'
2.12
V
FREQ'
50.0
Hz
-t
IV DC
lms/DIV
B2O0mVOFF
Trig:AJ
I
P/P:
1.44
V
FREQ'
50.0
Hz
1
1
1
1
\ \ !
\
1
1
1
"
1
SPECIAL FUNCT'
ft
f. - w
.
RUN
Figure 74Pa. Pilot Signal, Ruggedised Modem

Out of Circuit, Machine Stood.
"
1
I
I
V-Js
RUN
SPECIAL FUNCT'
Figure 74Pb. Pilot Signal, Ruggedised Modem

Out of Circuit, Machine Running.
166
A
IV DC
10ms/DIV
1
'
P/P:
2.16
V
FREQ:
50.0
Hz
1
1
1
1
A
IV DC
lOms/DIV
2O0mV OFF
Trig'AJ
J - =T- 1 " \ ~ '7 ~ *
~~i "
"
sr>
B200mV0FF
A
Trig: J
1
,
;
;
!
;
P/P:
1.44
V
FREQ'
50.0
Hz
~*\ ~ ~*~< "
l \ i
1
1
1
1
"
"
RUN
SPECIAL FUNCT:
SPECIAL FUNCT:
B 200mV OFF
Trig'AJ
<
\ ' t' I"

\\j
\
"
il
A
IV DC
lOms/DIV
1
1
1
1
SPECIAL FUNCT'
Figure 74Pe. Pilot Circuit

RUN
B 200mV OFF
Trig:AJ
P/P'
2.24
V
FREQ'
50.0
Hz
1
1
1
1
;
;
Figure 74Pd. Pilot Circuit Signal, Ruggedised

Machine Running.
Figure 74Pc Pilot Circuit Signal, Ruggedised

Machine Stood.
A
IV DC
lOms/DIV
1
P/P:
1.48
V
FREQ:
49.0
Hz
^j\pmi
"
HOLD
Signal,
RUN
SPECIAL FUNCT:
Data
Figure 74Pf. Pilot Circuit Signal,

167
Data
A200mVDC
lms/DIV
B2mV0FF
Trig=AJ
1
1
1
f
V-ftfl
SPECIAL FUNCT'
Figure 74Pg. Pilot Circuit Signal, Data

A200mVDC
IJJS/DIV
B500mV0FF
Trig'AJ
i
1
1
A 200mV DC
10JS/DIV
B500mV0FF
Trig'AJ
1 "I
P/P'
344
mV
FREQ'
61.0
kHz
1
1
fif 'A A
r\
J \j
1
1
1
-J
" 1
SPECIAL FUNCT'
Figure 74Ph. Data Signal Test Point 14,

RUN
SPECIAL FUNCT'
Figure 74Pi. Data Signal Test point 14,

168
A lOOmV OC
10US/DIV
B500mV0FF
Trig:AJ
A 1 mV DC
lOjjs/DIV
1
-'
B 500mV OFF
T r i g = AJ
1
/\
\ \
/:
324
mV
FREQ:
78.1
kHz
: \-1\ --\- \ \ - \\\1 \\ i \ i \ j \ \ / ! \

a J "IJ
"
SPECIAL FUNCT-
'
H\l
} f~i ri
QlEU llWd
\J [ ^
!
!
!
!
!
RUN
Figure 74Pk. Data Signal Test Point 14, Repeater

AlOOmV DC
10JJS/DIV
:
1
500mV OFF
Trig:AJ
'
SPECIAL FUNCT:
Figure 74Pj. Data Signal Test Point 14, Repeater

A lmV DC
10JJS/0IV
P/P:
128
mV
FREQ:
56.8
kHz
50OmV OFF
Trig'AJ
"1
1
anjiDJiCi
P/P:
136
mV
FREQ:
69.4
kHz
RUN
RUN
SPECIAL FUNCT:
SPECIAL FUNCT'
Figure 74PI. Data Signal Test Point 8, Repeater

Modem.machine stood.
Figure 74Pm. Data Signal Test Point 8, Repeater

169
4. Wallacetown SIMOS Gate End Box

The SIMOS gate end box is the latest design of switchgear from Wallacetown making use of digital
circuitry to provide the control functions and operational information, they are not widely used within
British Coal at the present time. The box tested was a double outlet type and configured such that one
outlet was operational with POIS, and the other outlet with POIS out of circuit.
4.1 Wallacetown SIMOS POIS Out of Circuit
With the machine power from the SIMOS gate end box with POIS out of circuit the test procedure was
observed and the following oscilloscope traces recorded. Figures SIMOSa-SIMOSm show the pilot and
data signals observed during the test.
function, Figures SIMOSa/b & SIMOSc/d. During the start/stop tests the data transmission system
stopped communicating 3 times on start up with registered errors in the data, recorded 5 starts at the
machine Trend'. Restarting the communication link after a transmission failure was not a problem.
A
IV DC
lOms/DIV
B2O0mVOFF
Trig'AJ
I
I
I
,
1
1
JV
A
IV DC
lOms/DIV
1
P/P'
3.76
V
FREQ'
50.0
Hz
ferV- f^~\- 1\- j 1 - . '

.
'\
l\
lT\
B200mVOFF
Trig'AJ
I
I
I
,
P/P'
2.48
V
FREQ'
50.0
Hz
I
"
RUN
SPECIAL FUNCT'
RUN
Figure SIMOSa. Pilot Signal, Ruggedised Modem

SPECIAL FUNCT'
Figure SIMOSb. Pilot Signal, Ruggedised Modem

170
A
IV DC
lms/DIV
,
1
B200mV0FF
Trig:AJ
1
1
1
1
1
"
P/P =
3.76
V
FREQ:
50.0
Hz
\ V* - '
( r j - 4 - -4-
A IV DC
10ms/DIV
'\ /
l\ /
\
\ .
1
1
..... .. ,
!
1
1
", 1
.
"
" V" "
RUN
Figure SIMOSd. Pilot Circuit Signal, Ruggedised

Machine Running.
20mV OFF
Trig=AJ
A IV DC
10ms/DIV
P/P =
3.84
V
FREQ:
50.0
Hz
P/P'
2.52
V
FREQ:
50.0
Hz
/VT u
V" "7" J"
>\
1
1
200mV OFF
Trig:AJ
A IV DC
10ms/DIV
l\
\1 1 \
1
V/
L_J
P/P:
2.48
V
FREQ:
50.0
Hz
SPECIAL FUNCT'
Figure SIMOSc. Pilot Circuit Signal, Ruggedised

Machine Stood.
RUN
SPECIAL FUNCT:
J V
200mV OFF
Trig:AJ
I
I
I
,
1V
Vn
'
HOLD
SPECIAL FUNCT:
SPECIAL FUNCT:
Figure SIMOSf. Pilot Circuit Signal, Data

Figure SIMOSe. Pilot Circuit Signal, Data

171
Figure SIMOSg. Pilot Circuit Signal, Data

A 208mV DC
lOjjs/DIV
al | A S
B500mV0FF
Trig:AJ
I
I
I
,
A 200mV DC
ljjs/DIV
P/P:
488
mV
FREQ:
65.8
kHz
"
;
;
!
/ =
352
mV
FREQ'
65.8
kHz
" "~\" \ " " "
f \
'\ \/ \ \ \ ' \
7 V \ f! "\"
.
.
1
500mV OFF
A
Trig: J
1
,
.
'
RUN
SPECIAL FUNCT:
Figure SIMOSh. Data Signal Test Point 14,

SPECIAL FUNCT:
;
;
; ;
!
HOLD
Figure SIMOSi. Data Signal Test point 14,

172
A 100mV DC
ljjs/DIV
I
B5O0mVOFF
Trig'AJ
'A
'
'
1
ftlOOmV DC
10JJS/DIV
:
P/P'
440
mV
FREQ'
75.8
kHz
500raV OFF
Trig'AJ
yf t l i "
jy
_ _
HOLD
SPECIAL FUNCT'
saiiai
SPECIAL FUNCT:
Figure SIMOSk. Data Signal Test Point 14,

Repeater Modem, Machine Running.
Figure SIMOSj. Data Signal Test Point 14,

Repeater Modem, Machine Stood.
A lOOmV DC
101IS/DIV
500mV OFF
Trig:AJ
AlOOmVDC
lOys/DIV
P/P'
144
mV
FREQ'
75.8
kHz
500mV OFF
Trig'AJ
:
1
P/P'
140
mV
FREQ:
69.4
kHz
v r~\ r^ r^1
LUWuh:
-+_i 1'-uJ_l)_LJ-c
*r-U
aj
'
M&E
SPECIAL FUNCT'
RUN
SPECIAL FUNCT:
Figure SIMOSm. Data Signal Test Point 8,

Figure SIMOSI. Data Signal Test Point 8,

Repeater Modem.machine stood.
173
4.2 Wallacetown SIMOS Gate End Box with POIS In Operation

With the machine power from the SIMOS gate end box with POIS in operation the test procedure was
observed and the following oscilloscope traces recorded. Figures SIMOSPa-SIMOSPm show the pilot
and data signals observed during the test.
function, Figures SIMOSPa/b & SIMOSPc/d. During the start/stop tests the data transmission system
stopped on 6 of the starts, and 6 times data transmission errors were registered at the machine Trend'.
Re-establishing the communication link after a break was not a problem.
A
IV DC
lOms/OIV
B200mV0FF
Trig:AJ
1
1
'
'
P/P =
3.80
V
FREQ:
50.0
Hz
P/P =
2.44
V
FREQ:
50.0
Hz
Lj_i- 411
200mV OFF
Trig;AJ
IV DC
lOms/DIV
"1
'
ft
' M\mi
1
1
'
RUN
"
SPECIAL FUNCT'
Figure SIMOSPa . Pilot Signal, Ruggedised

Modem Out of Circuit, Machine Stood.
I
1
\J
iV
RUN
SPECIAL FUNCT:
Figure SIMOSPb. Pilot Signal, Ruggedised

Modem Out of Circuit, Machine Running.
174
A
IV DC
lms/DIV
2O0mV OFF
Trig'AJ
'
P/P'
3.80
V
FREQ:
50.0
Hz
1
1
A
Li-i. j-\.
"
l\ /
| V
1
1
"
RUN
VJ!
\j
P/P:
2.44
V
FREQ'
50.0
Hz
<\f
1
1
RUN
SPECIAL FUNCT:
Figure SIMOSPc. Pilot Circuit Signal, Ruggedised

Machine Stood.
1
1
1
1
| V
SPECIAL FUNCT:
200mV OFF
Trig:AJ
I
I
I
,
w.m
\
Vi
A
IV DC
10ms/DIV
IV DC
10ms/OIV
1
B200mV0FF
Trig:AJ
I
I
I
,
Figure SIMOSPd. Pilot Circuit Signal, Ruggedised

Machine Running.
A
IV DC
lOms/DIV
I
P/P:
3.84
V
FREQ:
50.0
Hz
- A' j ' \-~.
!
;
;
;
"
"
SPECIAL FUNCT:
Figure SIMOSPe. Pilot Circuit Signal, Data

1
1
i j Ti
RUN
B200mVOFF
Trig:AJ
-~
jy.
,vy
/ \
A/
\j
|^
SPECIAL FUNCT:
P/P:
2.60
V
FREQ:
50.0
Hz
/ \ - i
\
w
'\L
V
!
!
RUN
Figure SIMOSPf. Pilot Circuit Signal, Data

175
A500mVDC
lOms/DIV
1
B200mV0FF
Trig:AJ
I
P/P'
2.60
V
FREQ'
50.0
Hz
1
1
"A
\
J
1 _1
"
il f
'l r
1' l
\
l
\
"
I
SPECIAL FUNCT:
"
mon
Figure SIMOSPg. Pilot Circuit Signal, Data

A 100mV DC
lys/OIV
,
B500mV0FF
Trig'AJ
I
' '
' A
'
P/P:
440
mV
FREQ:
75.8
kHz
'
7\ i
lii IJ 1 J \s
" Ju l
"
'
'
i\
'
'
1I
f -AL
"II
1
'
" 7 "
P/P'
424
mV
FREQ:
75.8
kHz
U
SPECIAL FUNCT'
50mV OFF
Trig-AJ
A lOOmV DC
lOjjs/DIV
l i .
ijiai
HOLD
"
Figure SIMOSPh. Data Signal Test Point 14,

SPECIAL FUNCT:
Figure SIMOSPi. Data Signal Test point 14,

176
A lOOmV DC
lOjjs/OIV
500mV OFF
Trig:AJ
ft 100/iV DC
lOjjs/OIV
500mV OFF
Trig:AJ
'[111
:::
SPECIAL FUNCT'
SPECIAL FUNCT
Figure SIMOSPk. Data Signal Test Point 14

Figure SlMOSPj. Data Signal Test Point 14

ft lOOmV DC
lOjjs/DIV
500mV OFF
Trig:AJ
aiiniuia
AlOOmVDC
10JJS/DIV
P/P'
144
mV
FREQ'
71.4
kHz
aj
^J.
500IBV OFF
Trig:AJ
1
1
fini
|P/P>
144
mV
FREQ:
71.4
kHz
lili*
HOLD
SPECIAL FUNCT'
SPECIAL FUNCT:
Figure SIMOSPm. Data Signal Test Point 8

Figure SIMOSPI. Data Signal Test Point 8

177
5. Baldwin & Francis FT/M11A Gate End box

5.1 & F P130
With the machine power from the B&F FT/M11A gate end box and a standard P130 pilot circuit in
operation the test procedure was observed and the following oscilloscope traces recorded. Figures
BFP130a-BFP130m show the pilot and data signals observed during the test.
the inclusion of the ruggedised modem in the pilot circuit caused no obvious deterioration of the pilot
circuit function, Figures BFP130a/b & BFP130c/d. During the start/stop tests the data transmission
system stopped on 2 of the starts, and data transmission errors were registered 11 times at the
machine 'Trend'. Re-establishing the communication link after a break was not a problem.
A 500mV DC
lOms/DIV
B200mVOFF
Trig:AJ
A500mVOC
10ms/DIV
1
B2O0mVOFF
Trig'AJ
I
I
I
,
P/P:
1.20
V
FREQ:
50.0
Hz
aj I
**
RUN
SPECIAL FUNCT=
SPECIAL FUNCT'
_-
Figure BFP130a. Pilot Signal, Ruggedised

Modem Out of Circuit, Machine Stood.
Figure BFP130b. Pilot Signal, Ruggedised

Modem Out of Circuit, Machine Running.
178
A 500mV DC
10ms/DIV
B200mV0FF
Trig=AJ
-1
1
1
P/P'
2.10
V
FREQ'
50.0
Hz
1
1
1 \J
\J
A 500mV DC
10ms/DIV
RUN
SPECIAL FUNCT:
SPECIAL FUNCT
Figure BFP130C. Pilot Circuit Signal, Ruggedised

Machine Stood.
Figure BFP130d. Pilot Circuit Signal, Ruggedised

Machine Running.
B200mV0FF
Trig'AJ
A500mVDC
lOms/DIV
.
I
I
i~~
ft
200mV OFF
Trig'AJ
t\~
A5O0mVDC
lOms/DIV
P/P'
2.16
V
FREQ'
50.0
Hz
1
1
1
1 li
I 1 -
f \
200mV OFF
Trig-AJ
I
I
I
,
P/P'
1.26
V
FREQ:
50.0
Hz
"
RUN
SPECIAL FUNCT'
Figure BFP130e. Pilot Circuit Signal, Data

RUN
SPECIAL FUNCT:
Figure BFP130f. Pilot Circuit Signal, Data

179
A280mVDC
lms/DIV
B200mVOFF
Trig:AJ
1
1
SPECIAL FUNCT:
Figure BFP130g. Pilot Circuit Signal, Data

AlOOmV DC
10JJS/DIV
I
; A
l - i r
>
-
--
P/P =
408
mV
FREQ:
73.5
kHz
' ' fi
/\' M
I
Y / \
1
1
AlOOmV DC
lOjjs/OIV
.
I
B500mVOFF
Trig'AJ
I 1
500mV OFF
Trig=AJ
1
'
]\ 1
1 1 _A _ _ L
aJ
l' /
i\
'
f \
'
if
P/P'
424
mV
FREQ:
59.5
kHz
y y i,
I
1
"
SPECIAL FUNCT:
"
mm
Figure BFP130h. Data Signal Test Point 14,

SPECIAL FUNCT:
ms
1
Figure BFP130I. Data Signal Test point 14,

180
A100mV DC
lOys/DIV
1
500mV OFF
Trig:AJ
1
A 100mV DC
lOys/DIV
P/P:
356
mV
FREQ:
69.4
kHz
'
7 V 1 \' I
-
|U
1
1
1
1
1
'
af J L J 1 J
1\
l/\
\ ~\J ' '
I
-
I
1
HOLD
B500mV0FF
T r i g = AJ
ii
iz*s - ^J-
"
- t_-c
AlOOmV DC
lOys/DIV
1
P/P'
144
mV
FREQ:
62.5
kHz
B5O0mVOFF .
Trig:AJ
I
I
I
,
P/P'.
144
mV
FREQ:
67.6
kHz
1
1
a
-r 1
"
-L'
-Ul-L'
L ^ - -kj,- C
USEM
~*\
*^>
-j
4
HOLD
Figure BFP130I. Data Signal Test Point 8,

Repeater Modem,machine stood.
Figure BFP130k. Data Signal Test Point 14,

SPECIAL FUNCT'
IMDH
SPECIAL FUNCT:
Figure BFP130J. Data Signal Test Point 14,

'
/ \ \
P/P:
364
mV
FREQ:
78.1
kHz
SPECIAL FUNCT=
A 100mV DC
10JJS/DIV
B500mV0FF
Trig-AJ
'
'
'
1
SPECIAL FUNCT
Figure BFP130m. Data Signal Test Point 8,

181
5.2 & F 1
With the machine power from the B&F FT/M11A gate end box and a BZ1 pilot circuit in operation the
test procedure was observed and the following oscilloscope traces recorded. Figures BFB21aBFBZ1 m
show the pilot and data signals observed during the test.
the inclusion of the ruggedised modem in the pilot circuit caused no obvious deterioration of the pilot
circuit function, Figures BFBZ1a/b & BFBZ1c/d. During the 20 start/stop tests the data transmission
system problems occurred after 11 starts with the machine not starting from the computer control. Of
the 10 starts and stops which were performed the transmission stopped once and transmission errors
were recorded on the machine Trend' 2 times. Re-establishing the communication link was not a
problem. A fault within the pilot circuit connections within the rig was thought to be the problem.
ft
IV DC
10ms/DIV
B200mV0FF
Trig'AJ
B200mV0FF
Trig'AJ
A
IV DC
10ms/DIV
1
1
1
1
n-rv rxrx
"
SPECIAL FUNCT'
1
I
1
1
SPECIAL FUNCT'
Figure BFBZIa. Pilot Signal, Ruggedised Modem

P/P'
1.40
V
FREQ'
50.0
Hz
,
I
1
1
1
1
1
1
1
1
1
1
1
1
1
RUN
Figure BFBZIb. Pilot Signal, Ruggedised Modem

182
A IV DC
10ms/DIV
ft IV DC
10ms/DIV
200mV OFF
Trig'AJ
1
1
1
|
uV r
~\
200mV OFF
Trig:AJ
P/P'
2.04
V
FREQ'
51.0
Hz
P/P'
1.40
V
FREQ'
50.0
Hz
jT^ at
RUN
I SPECIAL
RUN
I SPECIAL FUNCT:
FUNCT'
Figure BFBZId. Pilot Circuit Signal, Ruggedised

Machine Running.
Figure BFBZIc Pilot Circuit Signal, Ruggedised

Machine Stood.
A IV DC
lOms/DIV
'
L t" " " ' ~"
A IV DC
lms/DIV
B20OmVOFF
Trig:ftJ
1
'
'
1
P/P'
2.12
V
FREQ'
51.0
Hz
"X^nrf
\ 'mm
"
P/P1.48
V
FREQ'
49.0
Hz
RUN
RUN
SPECIAL FUNCT'
SPECIAL FUNCT:
Figure BFBZIe. Pilot Circuit Signal, Data

B 20OmV OFF
Tri g J
Figure BFBZIf. Pilot Circuit Signal, Data

183
B2O0mVOFF
Trig'AJ
ft500mVDC
1Oms/DIV
SPECIAL FUNCT'
Figure BFBZlg. Pilot Circuit Signal, Data

100mV DC
10JJS/DIV
' '
' '
1 \ ' 1 1 II
Vi \ 1 I
aj W
"
\l
ftlOOmV DC
10JJS/DIV
'
B500mV0FF
Trig'AJ
1
|
1
1
1
\J.
P/P'
416
mV
FREQ'
78.1
kHz
\ ' \
B508mVOFF
Trig'AJ
I
I
I
,
P/P'
436
mV
FREQ'
75.8
kHz
f u l l 11
ajW
l ' i lI i \
"
HOLD
SPECIAL FUNCT'
SPECIAL FUNCT'
Figure BFBZIh. Data Signal Test Point 14,

1
I
I
I
amai
"
Figure BFBZ1I. Data Signal Test point 14,

184
A 100mV DC
lOys/DIV
B500mV0FF
Trig=AJ
'
AlOmVDC
lOjjs/DIV
/'
316
mV
FREQ'
78.1
kHz
]j~V'\j"\j'V~
"
SPECIAL FUNCT:
aj_w_
>
'
'
"
"
500mV OFF
Trig:AJ
I
I
I
,
J.-
*~
I
I
KSBiK
SEOHI
SPECIAL FUNCT'
Figure BFBZIk. Data Signal Test Point 14,

AlOOmV DC
10US/DIV
P/P'
140
mV
FREQ:
67.6
kHz
j '
'
L
f\
Figure BFBZ1J. Data Signal Test Point 14,

ftlOOmV DC
10JJS/DIV
f\
]\ L _ _ .(]
li A
I
-Yl
\ I
W \ / W \ /J \ i
;
!
P/P'
372
mV
FREQ'
69.4
kHz
-A '
'
7 \' / \ \ \ \ 7 \
I
500mV OFF
Trig'AJ
I
I
I
,
j '
A
~1
if
..
500mV OFF
Trig'AJ
P/P'
140
mV
FREQ:
78.1
kHz
DTJTTTjun;
SHH
'
SPECIAL FUNCT'
Figure BFBZ1I. Data Signal Test Point 8,

Repeater Modem,machine stood.
suon
SPECIAL FUNCT:
Figure BFBZIm. Data Signal Test Point 8,

185
6 Baldwin & Francis BFS Gate End Box

The most recent type of gate end box from B&F is the BFS, this box uses digital electronics to monitor
various function of the gate end box operation. The pilot circuit differs from the others tested as it uses
a squarewave pilot signal, with a frequency of 1KHz (See flgiure BSFa) as opposed to the normal
50Hz sinewave signal of the other gate end box circuits. Connection onto the pilot core of the trailing
cable also proved a problem as the remote start circuit is separately monitored by the BFS box. A
separate connection onto the pilot circuit had to be made inside the GEB to enable the test to be
carried out.
The link along the pilot core was tested using the communication system with the gate end box
switched off. As soon as the pilot circuit was energised it became impossible to establish two-way data
communication along the pilot core. It appeared that the 1 KHz pilot signal was interfering with the data
stream. To enable some tests to be carried out on the effect of tarnsmitting data along the pilot core,
a protocal analyser was used in place of a one of the Trend's to enable repetitive one-way
transmission of data from surface to machine.
With protocal analyser generating data the pilot circuit operation was tested the machine was started
and stopped successfully a number of times withought any effect from the data communication signal
on the line. Figures BFSbg show the pilot circuit signal during the pilot cxircuit tests,
he signal being recieved at the ruggedised modem were monitored and recorded (See Fig BFSh-k).
It was apparent from the traces that the square wave edges were interfering with the data stream,
causing the modem to falsely interpret the harmonics of the square wave as data.
A 500mV OFF 10 ' 1 PROBE 500mV DC

500JJS/DIV
Trig = AJ
P/P-
2.04
V
mm
SPEC I All FUNCT'
Figure BFSa. Raw Pilot Signal @ Gate End Box

No Modems Fitted, Machine Stood.
186
A 5VAC 10:1 PROBE 1OV OFF

500US/DIV
Trig:AJ
I
1
1
1
1
A 5VA C 10=1 PROBE 10V0FF

500JJS/DIV
A
Trig: J
FREQ:
943
Hz
RISE:
260
JJS
RUN
SPEC I All FUNCT'
Figure BFSb. Pilot Circuit Signal, Ruggedised

Modem Out of Circuit, No Data Transmission,
Machine Stood.
A 5VAC 10=1 PROBE 10V OFF

500JUS/DIV
Trig = AJ
| "
|j
Figure BFSc. Pilot Circuit Signal, Ruggedised

Modem Out of Circuit, No Data Transmission,
Machine Running.
A 5VA C 1 0 : 1 PROBE 10V OFF

5O0S/DIV
A
Trig: J
, FREQ:
943
Hz
RISE:
220
SPEC I All FUNCT:
FREQ:
962
Hz
RISE
???
US
1/
. Ui U U .
kf
| 1
' RUN
Figure BFSd. Pilot Circuit Signal, Ruggedised

Machine Stood.
y
RUN
SPEC I All FUNCT:
Figure BFSe. Pilot Circuit Signal, Ruggedised

Machine Running.
187
A 5VAC PROBE 10VOFF

500JJS/DIV
Trig'AJ
A 5VAC PROBE lOV OFF

500JJS/DIV
Trig'AJ
1
1
1
1
r[\P[f
; FREQ'
962
Hz
RISE'
???
'
\Py
RUN
SPEC I All FUNCT
Figure BFSf. Pilot Circuit

Transmission, Machine Stood,
SPEC I All FUNCT'
Signal,
Data
'
Figure BFSg. Pilot Circuit Signal,

Transmission, Machine Running.
Data
ft 2VAC 10 PROBE B500mVDC

500JJS/DIV
Trig'AJ
I
1
1
1
1
1
SPECfftL FUNCT
Figure BFSh. Data Signal Test Point 14, & Pilot

Circuit Signal, Ruggedised Modem, Machine
Stood.
Figure BFSi. Data Signal Test point 14, & Pilot

Running.
188
A 50OmV AC 10 lPROBEB500mVDC
Trig'AJ
500JJS/DIV
1
A 500mV AC 1 0 : 1 PROBE 500mV DC

500JJS/DIV
Trig:AJ
J JL
hr w HIIII
A
L~-i
^^
SPECIAL FUMCT:
HOLD
SPECIAL FUNCT'
Figure BFSj. Data Signal Test Point 8, & Pilot

Stood.
Figure BFSk. Data Signal Test Point 8 & Pilot

Circuit, Ruggedised Modem, Machine Running.
7. Conclusions
With the exception of the BFS gate end box which required the data to be forced along the pilot
waveform, all the pilot circuit tests proved successful in enabling a two-way data communication system
to operate. Neither the insertion of the ruggedised modem in the circuit or the data communication
signal caused any interference in pilot circuit operation. The machine was always under full pilot circuit
control. The problem of the data transmission errors or transmission failure on start-up will not be a
problem in normal pit operation as the data communication link is not established until after power-up.
The start/stop tests were carried out to simulate a higher motor load, since this was the only method
of generating a higher current through the trailing cable. The results of the start/stop tests do not give
a clear indication of the effect of a high current within the trailing cable and their result on pilot circuit
and data communication operation. The BFS box pilot circuit was also operated correctly with the
insertion of the ruggedised modem and data transmission having no effect upon the pilot circuit
operation. Further work will be required to stop the square-wave pilot signal from corrupting the data.
189
APPENDIX 5
Monitoring of Roadheaders
Surface Monitoring Functional Specification
Introduction
Monitoring systems for roadway drivage machines consist of 3 identifiable parts. The
underground data acquisition system and transducers, the machine to surface transmission
system and the surface computer installation for data presentation and analysis. The
monitoring system for roadway drivage machines currently under development will utilise
MACE (Multi-purpose Automation and Control Equipment) to acquire data from various
transducers and sensors. The data collected will then be transmitted via a British Coal
standard HDLC transmission system to the surface where a DEC VAX Station running a
propriety software package will analyze and display the data.
This document is concerned with functional specification of how the data is to processed by
the surface computer, and define the method of data presentation via the surface computer
monitor.
The monitoring system addresses two different areas of roadway drivage machine monitoring,
performance and health. Performance monitoring enables the identification of the drivage
machine's utilisation and operation, by presenting the cutting, loading and advancing
procedures at the surface. Condition monitoring assesses the health of the drivage machine
by the identification of faults within the machine's services which may lead to machine
stoppages, ie low hydraulic level, and electric motor temperature, etc. To give a true
representation current machine condition/operation all the necessary data must be easily
accessed and clearly displayed to the system interrogator.
Surface Data Acquisition System Requirements
Surface Hardware and Data Transmission Configuration
The surface data acquisition system will be managed by either DEXTERITY or G-Fics
SCADA (Supervisory Control And Data Acquisition) software, both systems having an almost
identical composition. Dexterity is currently being developed to emulate and improve the
already used SUMMIT system for shearers. The current development work is being directed
to the operation of the software on a DEC VAX Station. This work will give a solid base for
configuring and commissioning the roadheader monitoring system, The roadheader surface
monitoring package will make use of some of the function developed for the shearer
monitoring system.
For the VAX station to communicate with the MACE communication system it is necessary
for the transmitted data to be conditioned within a 'Gateway'. The 'Gateway' is basic 386 AT
PC which converts the incoming data from HDLC MACE application protocol (Detailed in
the Application Sheet for Monitoring of Roadheaders using MACE) to TCP/IP on Ethernet.
(Figure 1 illustrates the complete transmission system for the roadheader system). The data
is then sent over the Ethernet line to the VAX running DEXTERITY by an interface program.
A VAX station driver is currently under development and recent tests have shown it to be
functional.
The 'Gateway' software is available in development form and requires a standard 386 AT PC
fitted with Ethernet & EMULEX cards.
193
Surface Software Requirements & Specification

The interface between man and computer systems relies heavily on visual representation of
the information retrieved. Design and specification of how the data is to be represented both
in visual form on the terminal and hard copy printed format is detailed in following text. The
generation of alarm messages is also considered. The displays and reports relate to the
application of the monitoring system fitted to a Anderson Strathclyde RH 1/4 roadheader at
the TSRE trial site at Middleton Mine, Wirksworth. Display data in machine monitoring can
be separated into two areas:
Directly measured transducer values
derived values (for example cutting head position)
It is anticipated that as experience is gained in the use of such a surface facility for
roadheaders the specification of other displays and reports generated for further derived
parameters may be necessary.
The following displays are specifically designed for the Middleton Mine trial and the displays
are kept to the minimum that will enable all the necessary data to be presented to a system
operator. These displays are likely to form a base for a colliery based system but it is
probable that as experience is gained and other system requirements identified the display will
be added to and modified.
Performance Monitoring Displays
Data analysis and surface display design for performance monitoring will enable the PC
operator to access information regarding the drivage machine's utilisation. Unlike the
SUMMIT system for shearers which references machine movement to the face line, no facility
of direct measurement of advance exists for drivages. Therefore all the trend displays will be
time based. By data interpretation and mathematical manipulation the surface system should
be capable of identifying the various parts of the drivage cycle.
These are:a)
b)
c)
d)
Machine cutting next section of advance.

Machine loading and clearing out cut material.
The setting of the roadway support, (either Arch or Bolting).
Machine advancing to cut next section of roadway.
Ideally each of these parts of the drivage cycle should be identified separately, but it is
assumed that some loading will be concurrent with the cutting of the roadway section.
Problems in the identification of machine advance are anticipated, as no facility of measuring
machine advance relative to a fixed reference point in the previously cut roadway currently
exists. Therefore it is intended to use chronological trend analysis on a shift/daily time base
to determine the number of complete cycles performed. This will then directly relate to
advance rate in supports set but not in precise metres advanced. The trial at Middleton Mine
will give an insight into how practical and accurate this form of machine advance can be, and
if this facility is a requirement for a colliery based system. It should be appreciated that
different levels of management and areas of the industry will have differing views on the
194
importance of the various monitoring functions available.

Surface Performance Monitoring Displays and Report Generation
The surface displays form the vital link between the colliery staff and the data being acquired
by the MACE unit on the drivage machine. The displays should be self explanatory with only
information relevant to the function being displayed being included within the terminal frame.
The initial configured displays for performance will be:a)
b)
c)
d)
e)
Machine Current Utilisation

Boom Position (Area Cut) (Derived)
Debris Clearance System
Machine Utilisation History (Derived)
Machine Advance History (Derived)
The considered areas of report generation are as follows:a)

b)
Machine Utilisation (M/C Running Time)

Number of Cycles Cut and Roof Supports Set (Calculated)
Figure 2. shows gives a typical flow diagram for both performance and health monitoring, of
how each display will be prioritised and accessed via menu options.
Display A: Current Machine Utilisation
The display of Current Machine Utilisation will give the terminal operator a visual
representation of the machine and indicate which services are currently in use. This will allow
the operator to expand to another display and examine in more detail the functions of the
machine. The display will indicate the following operations:i)
ii)
iii)
iv)
v)
vi)
Boom Operation
Cutter Motor Operation
Power Pack Motor Operation
Debris Clearance System Operation
Track Operation
Apron Operation
Figure 3. shows how the display for Current Machine Utilisation will look to the system
operator. Each section of the display relies on detecting the operation of specific machine
services. By the application of mathematical functions each operation can be represented.
Figure 4 gives the algorithm flowchart demonstrating the considerations of each specific
operation.
195
Display : Boom Position

The display of boom position will allow the operator to see the state of the current cutting
cycle. This display will indicate the following functions:i)
ii)
iii)
v)
Cutting Head Position within the Face

The Percentage of the Current Face Cut
Cutter Motor Power
Time of Current Cut
The majority of the above parameters require derivation from the raw data coming form the
drivage machine. Some difficulty will be experienced in the determination of the start of
various machine procedures but in the derived algorithms these are overcome with
mathematical manipulation. Figure 5 shows a sample layout of how the display is to be
presented and Figure 6 covers the flowchart algorithms required to enable the display to be
generated.
Display C: Debris Clearance System
The Debris Clearance Display gives a detailed representation to the operator of the current
state of all the debris clearance equipment The display will provide the following
information:i)
ii)
iii)
iv)
v)
vi)
Gathering Arms Operation, Left & Right

Chain Conveyor Operation
Chain Conveyor Motor Power
Bridge Conveyor Operation
Tracks Forward
Apron Sump Control
The variables governing the generation of this display are generally directly measured by
sensors and transducers fitted to the machine, requiring minimum variable derivations. Figure
7 gives an indication of how the information is to be presented to the operator. This display
incorporates two variables represented as bar charts which is a function currently available
on the DEXTERITY system.
Display D: Machine Utilisation History
This display is the first which is representing historical data. This display relies on data from
the previously detailed displays being collected and analyzed and then stored over a
predetermined time period (ie shift, day, week, month) for the generation of a graphical trend.
As directly accessible storage space is limited within the system only information which is
of operational importance should be allocated to trend generation.
The Machine Utilisation display will give an indication of how the machine has been operated
over the set time period. Highlighting the time spent on cutting, loading, machine running but
neither cutting or loading, and machine stood. Over longer periods of time this will enable
a report to be generated detailing the percentage of cutting time per shift. The ability to
portray the information accurately of Machine Utilisation may require more than one display
196
in this section. The displays will be graphical, either in the form of histograms or Une graphs.
Figure 8 gives a representation of the type of display to be generated with Figure 9 giving
the algorithms to enable a overall indication of machine utilisation to be generated.
Display E: Machine Advance & Utilisation History
It will be possible from the measured and derived parameters and by data manipulation will
allow the presentation of metres cut or cycles complete to be available in the form of a
graphical display or a hard copy report. As this method of determining the advance of a
drivage is prone to error the parameters used to generate it must also be available for
interrogation by the operator. This display will be in the form of a line graph or histogram
and will utilise the information generated for the Machine Utilisation display. Figure 10
illustrates how the information is to be presented to the operator and Figure 11 covers the
algorithms to enable the display and hardcopy reports to be generated.
The hardcopy report will give an estimated of the number of supports set/metres advance on
a shift/daily (weekly) basis.
With future developments it is expected that an accurate method of determining machine
advance will be available and be linked into the performance monitoring function.
As experience is gained in the use an flexibility of the surface monitoring package it is
anticipated that further displays may be needed to accurately represent the performance of a
drivage and the drivage machine. Other types of machine may incorporate additional or
alternative sensing equipment which may give better visibility of the performance parameters
involved in display generation.
Health Monitoring Displays and Report Generation
The sensors dedicated to health monitoring of the drivage machine have been installed to
monitor items of equipment relevant to good performance. If these parameters are allowed
to enter an alarm condition it makes the possibility of stoppage or reduced performance more
likely. Many of the transducers are dedicated to ensuring a good hydraulic supply to the
machine's services since these are important for good drivage performance. Table 1, gives a
list of all the health transducers currently available on the machine, and the derived variables
which are required to generate the surface displays. As health monitoring is mainly concerned
with actual real time parameters very few derived variables are required within the health
monitoring displays. It is anticipated that in future applications some other health monitoring
transducers may be required to satisfy different operators criteria. These may include derived
variables for example the efficiency of the power pack, or a specific hydraulic service.
The detection of deterioration in any of the health monitoring parameters will only be visible
when examined over an extended period of time. Therefore much of the health data is to be
stored so that trends can be established over a preset period of time (ie weekly, monthly).
197
The Health Monitoring displays will cover the 3 main services to the drivage machine, these
are:i)
ii)
iii)
Hydraulic Services
Electrical Services
Water Supply
Each services will have its own subsequent display enabling all the health parameters to be
presented to the operator effectively.
Hydraulic Service Displays
The hydraulic services will be represented via a number of displays which will allow the
presentation of specific aspects of the machine's hydraulic system. Some of the displays will
be mimics of the various circuits, but the ability to display all the transducer values relating
to a specific parameter (e.g. hydraulic flows, pressures, temperatures etc) in textural form are
to be included.
The most important hydraulic display will represent the parameters concerning the power pack
and the supply of efficient hydraulic power. This display will be in the form of a mimic
highlighting the various parts of the power pack circuit. The relevant transducer values will
be superimposed upon their respective symbols within the circuit. Figure 12 shows how the
display for the power pack services is to be presented to the operator.
As most drivage machines use positive/fixed displacement pumps for their hydraulic power,
a trend of the flowrate from each particular pump will be used to determine any deterioration
in pump performance. This may be extended to cover complete power pack efficiency at a
later stage. See figure 13 which shows a graphical illustration for the trend of pump flow.
A mimic display giving an overall indication of the conditions of all the filters within the
complete hydraulic system will enable the operator to plan maintenance procedures. Figure
14 shows how the display is to be presented to the operator. Pressure line filter monitoring
relies on differential pressure sensor which are viscosity (temperature) dependant, giving a
digital on/off output. An algorithm is given in figure 15 which allows for the oil temperature
to be considered before an alarm state is signalled.
Transducer values relating to a specific item of equipment will also be made available, for
example all the transducers relevant to Pump No 1 etc. The presentation of current transducer
values will be available in 2 forms either as bar graphs or textual depending on the operators
preference. The facility of the bar graphs to show the maximum and minimum values over
a set time period will also be available (as shown in figure 7).
The operator will be able to access all the raw data from the performance related transducers
from within the health option. These will be presented as either text or bar graphs. This will
allow an operator to ensure all the function of the monitoring system are operating properly.
The digital pressure switches used to determine the operation of individual machine services
shall be available as a health display option. They will be presented in a form of on/off for
each switch. Giving the operator full access to all system sensors.
198
Electrical Services Displays

The monitoring of the electrical equipment on the machine is devoted to the supply and
operation of the electric motors. This display will enable the operator to examine the current
state of all electric motors, the power being used by each and the operating temperature of
cutter and power pack motor. Details of the water circuit will be included to show that
cooling water is being used. Figure 16 shows how the display is to be presented to the
operator and the information to be included.
The cutter motor power will be made available as a graphical trend which may be used to
examine periods of overload which may occur during the cutting operation.
Water Supply Display
Water is supplied at a constant pressure and used by the machine for various functions. The
pressure and flowrate of the water circuit will be represented in both textural and graphical
bar chart form. Pressure will indicate if a water supply is available and flowrate used to
determine if water is actually being used. Different drivage machines use water for further
other operations and other displays may be required to cover the operation of air movers and
high pressure assisted cutting equipment. Figure 17 shows how the water circuit is to
presented to cover just water inlet pressure and flowrate. Figure 18 shows how a mimic
display would be used to portray a more typical drivage machine water circuit.
Display Priority
Once a drivage machine monitoring system is installed at a colliery each display will be given
a priority code. This will restrict each system operator to the displays which their
authorization code permits. For the demonstration trial at Middleton Mine all the displays will
have the lowest priority, making them accessible for viewing by any operator. The facility to
edit existing or develop new displays and their variables will be restricted to authorised
personnel only.
199
Figure 1. MACE Communication System

for Roadheaders
Supervisory
Computer
DEC
VAX Station
PC Gateway
Ethernet
RS232
Surface
Interface
LS.
Type 492
Telephone
Cable
MACE HDLC
Type 7
Trailing
Cable
HDLC
Pilot Core
Transmission
Gate End
Box
FLP
Type 62
Pilot
Cable
V/////////////////////////////////////////////
MACE HDLC
MACE HDLC
Roadheader
Power
Control
Box
MACE
Modem
7////////////////,
FLP
Type 62
Pilot
Cable
I. S HDLC
MACE Protocol
9.6kb/s
Gate-end
repeater
E-Type
DC2
Power
Supply
ROADHEADER
Transducers
HEALTH 1
PERFORMANCE
HYDRAULIC
ELECTRICAL
REAL TIME
HISTORICAL
PERFORMANCE
WATER
MACHINE
UTILISATION
MIMIC
AREA
OF
CUT
MIMIC
MACHINE
ADVANCE
GRAPH
MACHINE
UTILISATION
GRAPH
L
HISTORICAL
REAL TIME
DEBRIS
CLEARANCE
WATER
CIRCUIT
WATER
CIRCUIT
MIMIC
TRANSDUCERS
TEXT
MIMIC
ELECTRICAL
SYSTEM
TRANSDUCERS
TEXT
CUTTER
MOTOR
POWER
GRAPH
ELECTRICAL
SYSTEM
MIMIC
POWER
PACK
MOTOR
POWER
GRAPH
DIGITALS
& BOOM POSITION
TEXT
M
O
M
HISTORICAL
REAL TIME
TRANSDUCER
DISPLAYS
TEXT
HYDRAULIC
SERVICES
MIMIC
POWER
PACK
MIMIC
TRANSDUCER
DISPLAYS
BAR GRAPHS
OTHER
FILTER
CONDITION
MIMIC
PUMP 1
CIRCUIT
TRANSDUCERS
PRESSURE
TEMPERATURE
FLOWRATE
SUCTION
PRESSURE
OTHER
PRESSURE
TEMPERATURE
PUMP2
PUMP 3
TREND GRAPHS
FLOWRATE
SUCTION
PRESSURE
Figure 2. Flowchart Showing Display Priority and Access
OTHER
NOTES:
CURRENT MACHINE UTILISATION

CUTTER MOTOR POWER
CURRENT CUTTING TIME
This display is
intended to give
the operator an
indication of the
equipment currently
being used on the
drivage machine.
The colour of each
particular item labeled
Indicates if the item
is in use or not
Only the Cutter Power,
Time of Cut and Machine
Volts are Analogue
Readings
0000 KW
0000 MINS
HYD FILTERS
UI
O
WATER
FLOW
Figure 3. Current Machine Utilisation Display
CUTTER MOTOR
M/C VOLTAGE
GATHERING ARMS
YES
CUTTER
OFF
CUTTER
ON
POWER
OFF
DISPLAY
CUTTER
POWER
KW
NO
TRANSMISSION
POWER
ON
CHAIN CONVEYOR
CONVYR
STOOD
YES
OFF
CONVYR
RUNNING
FILTERS
CLEAR
Figure 4a.
FILTERS
BLOCKED
APRON
STOOD
Algorithms for Current Machine

Utilisation Display
APRON LIFT
APRON
LIFT
TRACKS
FRWD
START OF CUTTING
WHEN
START OF CUT
= TRUE
OFF/ LH OR RH\ ON
\
/
\
BOOM\
CENTRED x NO
(0.0)
/
"
OFF/ LH OR RH\ ON
TRACKS
FORWARD
|YES
\BKWRD/
TRACKS
STOOD
TRACKS
BACKWARD
START
TIMER
WHILE % FACE CUT

< 97% OR
CUTTER MOTOR POWER
> 0 0 KW
KEEP TIMING
& DISPLAY PARAMETER
o
UI
TRACKsX NO
< LH & RH .
\FORWARD/
|YES
EXIT
/
\
TELE \
BOOM x NO
EXTEND /
YES
STOP
TIMER
/
CUTTER\ NO
<
POWER ,
\ > 50 KW/
| YES
START
CUTTING
= TRUE
Figure 4b.
Algorithms for Current Machine

Utilisation Display
11
START
CUTTING
= FALSE
BOOM POSITION
M
O
HEAD POS
000
CUTTER MTR 000 KW

% FACE CUT 000 %
000 Y
WATER FLOW 000 GPM

WATER PRESS 0000 PSI
CUTTING TIME 000 MINS
Figure 5. Boom Position
NOTES:
This display will indicate
how the machine operator
is progressing with the
current cutting procedure.
Colour of the cutting head
within the roadway section
will Indicate cutting If
cutting Is In operation.
The roadway section will
fill as the cut area increases
until the full cross section
has been covered. Indicating
a face cut
For the machine to advance
1 metre or 1 roadway support
more than one area of face
will require cutting out.
Boom position Is a derived
calculated from the boom
slew and lift sensors. Boom
position is drivage machine
dependent requiring detained
information on machine
dimensions.
% OF FACE CUT
WHEN START
OF CUTTING
= TRUE
BOOM POSITION
V
GET SLEW
ANGLE
(SA)
See Figure
4b
GET LIFT
ANGLE
(LA)
X CO-ORD=
BOOM SLEW AXIS * SIN(SA)
RESET
% OF FACE CUT
ARRAY
M
O
^1
Y CO-ORD=
BOOM LIFT AXIS * SIN(LA)
WHILE CUTTER POWER

> 50 KW
EXIT
CALCULATE
BOOM POSITION
& SET ARRAY
CALCULATE
% OF FACE CUT
& FILL BOX ON DISPLAY
Figure 6.
DISPLAY
BOOM POSITION
&
(X,Y) CO-ORDINATES
CUT FACES =
CUT FACES+1
Algorithms for Boom Position Display
NOTES:
DEBRIS CLEARANCE SYSTEM

CURRENT OPERATIONS
ro
o
oo
APRON
SUMP
CHAIN CONV PWR 0 0 0 KW
KW
400
200
BRIDGE CONVEYOR
MAX
PSI
1200
MAX
600
Sooom
CUTTER MOTOR
POWER
urn
MIN
000
This display will give an

Indication to the operator
the current state of the
debris clearance system.
The boxes representing
individual Items of plant
will be colour coded to
indicate operation.
The cutter power and
chain conveyor tension
will be represented as
bar graphs as shown.
000
CHAIN CONVEYOR
TENSION
Figure 7. Debris Clearance System Current Operations
NOTES: -
MACHINE UTILSIATION HISTORY
This display enables the

operator to see the utilsatlon
of the machine over a period
of time. The time base for the
trend graph will be selected by
the operator. The time base options
available must Include Hourly.
Shift and Daily.
The facility to produce a hardcopy
of this display Is essential.
HOURLY
M/C CUTTING
M/C CUTTING
& LOADING
M/C LOADING
f\j
M/C RUNNING
M/C STOOD
8.00
9.00
10.00
11.00
12.00
13.00
14.00
TIME
Figure 8. Machine Utilisation (Hourly)
Figure 9. Algorithm for Machine

Utilisation (Hourly)
GATHERING ARMS
AND
CHAIN CONVEYOR
AND
BRIDGE CONVEYOR
ARE OPERATING
THEN M/C LOADING
MACHINE HISTORY
NOTES: -
MACHINE CYCLES
CYCLES
COMPLETED
This display allows the operator
to determine how many roof
supports have been set This Is
achelved by Identifying the
cyclic nature of Ihre drivage
and looking at the number of
repititions.
The display also gives an
Indication to the machine useage
and gives the machine running
time as a percentage of the total
shift time.
A
MON
NJ
M/C RUN TIME

% OF SHIFT
100
TUE
WED
THUR
FRI
MACHINE RUNNING
50
Figure 10. Machine Advance & Running History
The ability to produce a

hard copy of this display
Is essential.
MACHINE CYCLES
END OF
SHIFT/DAY/WEEK
GET NUMBER OF FACES CUT

SINCE LAST TIME PERIOD
No OF M/C CYCLES=
NUMBER OF FACES CUT
NUMBER OF FACES PER M/C CYCLE
STORE M/C CYCLES

SHIFT/DAY/WEEK
DISPLAY & PRINT

AS REQUESTED
M/C UTILISATION
SHIFT/DAY/WEEK
IF
POWER PACK
MOTOR POWER
> 10 KW
THEN TIME RUNNING
CALCULATE AT END OF EACH

SHIFT/DAY/WEEK
% OF MACHINE RUNNING TIME
DISPLAY & PRINT

AS REQUESTED
Figure 11. Basic Algorithms for Machine Advance &

Running History
POWER PACK HYDRAULIC SERVICES STAGE 1
HYDRAULIC
TANK LEVEL
NOTES:
This display allows the
operator to examine the
current condition of all
the hydraulic deliveries
form the power pack.
OIL TEMP
000 C
This display shows on of

the typical multi-stage
pumps used on drivage
machines. There would be
a display available for
each of the multl-stege
pumps In operation.
(3 on RH 1/4. 9 pumps in
total)
SUP PRESS
0000 PSI
PUMP Noi
SUC PRESS
FLOWRATE
000 GPM
00 PSI
An alarm would be signalled

if any of the parameters
measured entered an out of
range state.
SUP PRESS
0000 PSI
SUC PRESS
-
STAGE 2
FLOWRATE
000 GPM
00 PSI
SUP PRESS
0000 PSI
SUC PRESS
-
00 PSI
STAGE 3
FIWRATE
SUP TEMP
000 GPM
000 C
Figure 12. Display of Power Pack Pump Nol Hydraulic

Service Monitoring
NOTES:
HYDRAULIC POWER PACK PUMP 1

FLOWRATE TRENDS
GPM
This display shows the trend

of flowrate for each section
of a mulit-stage pump. There
would similar display for each
mutl-stage pump driven
by the power pack motor.
30
28
26
24
PUMP 1 STAGE 1
22
I I I I I I I I I I I H i l l I U I I I M I M I I I H I I I I I I I I H U I I I I M M I 11111 j 11111111111111 I I I H I I I H i l l [ I I I I I I I ! I I I I I I I I M I N I I I I I I I I U I I I I I M M I I I I I l l l |
WEEK No 1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
PUMP 1 STAGE 2
22
1111111
WEEK No 1
GPM
1 1 1 1 1 1 1 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 J 1111 1111 11111 1 1 1 1 1 1 111 111 111i 1111 1111 11111 11
10
11
12
13
14
15
16
11 1 1 )
17
18
1111 1111 1111111
19
20
21
22
'
23
24
30 28 26
24 22
PUMP 1 STAGE 3
WEEK No 1
u n i n m i i r m n i n i m m n i m u n i n m u m i i m i 111 I M m i n m m m i n u m i '
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Figure 13. Display of Hydraulic Pump Flowrate Trends
HYDRAULIC FILTER CONDITIONS PUMP Nol

SUC PRESS
PRESS FILTER
- 00 PSI
OK/BLOCKED
SUCTION
FILTERS
PRESSURE
LINE
FILTERS
SUC PRESS
PRESS FILTER
- 00 PSI
OK/BLOCKED
SUC PRESS
PRESS FILTER
- 00 PSI
NOTES:
This dispaly presents to the
operator all the information
for all the filters within the
hydraulic clrulL The suction
line filters efficiencies are
checked by a vacuum transducer.
An alarm will be indicated when
the transducer value reaches a
preset limit
The pressure line filters are
digital state and Indiente if
the filter Is either OK or Blocked.
It will be necessary for some
temperature compensation which
will ensure the filters are only
Indicating a blocked state once
the oil has reached operating
temperature.
OK/BLOCKED
RETURN LINE
FILTER
OK/BLOCKED
Figure 14. Hydraulic Filter Condition Display for Pump Nol
IF FILTER 1 OR FILTER 2
OR FILTER 3 OR
FILTER X
= TRUE
DISPLAY FILTER
BLOCKED
Figure 15. Algorithm for Blocked Filters to take

Account of Oil Viscosity
M/C ELECTRIC SERVICES

WATER
FLOW
000 GPM
M/C VOLTS
0000 V
^1
TEMP
000 C
Figure 16. Electrical Services Display
NOTES:
This display enables the operator
to see the current state of the
the electric motors. The operating
temperature and if cooling water
s being used.
NOTES:
M/C WATER CIRCUIT
WATER
CIRCUIT
PRESSURE
WATER
CIRCUIT
FLOW
000 PSI
000 GPM
oo
Figure 17. Basic Water Circuit Mimic
Dual
Filter
Pressure
Gauge
500 psi
Reducing
Valve
0000 PSI
000 GPM
NOTES: -
Pressure
Gauge
600 psi
Relief
Valve
-txj-
^ ~ ^ >
0-20 GPM
Flowmeter
Hydrocyclone
Filter
The circuit also gives an

alternative method for measuring
cutter motor operating temperature,
by using to temperature transducers
In the Inlet and eilt lines for the
coololng water. This method would
be mainly adopted for fitting to
drivage machines already underground.
0 - 5 GPM
Flowmeter
Stop
Valves
This display shows how a typical

drivage machine water circuit
fitted with additional equipment
can be instrumented to give the
operator an acurate picture of
water utilisation.
Oil Cooler
Fire Hose
GO
Pressure
Transducer
Temperature
Transducer
F
000 C
Cutter
Motor
000 c
Flow
Transducer
cm
Intensifier
Power Pack
Motor
00000 PSI
-
Discharge Option
on to Conveyors
During Non-Culting
Operations
4Z \f
Manual
Diverter
Valve
oooo PSI
Combined
Pressure/Flow
Switches
Air Movers
Figure 18. Typical Drivage Machine Water Circuit

Fitted with High Pressure
Water Jet Assisted Cutting
Table 1. Machine Variables Real and Derived

Real Analogue: Tank Oil Level
Boom Slew Angle
Boom Lift Angle
Conveyor Tension Pressure
Conveyor Operating Pressure
3 Suction Pressure
Cutter Motor Temperature
Hydraulic Oil Temperature
Pump 1 Flowrate
Pump 2 Flowrate
Pump 3 Flowrate
Water Circuit Flow
M/C Voltage
Cutter Motor Power
P/Pack Motor Power
Chain Conveyor Power
0.4 - 2.0 volts

+/- 45
+/- 45
0 - 2500 psi
0 - 2500 psi
0 - 2500 psi
0 - 1200 psi
0 - 2500 psi
0 - -1 bar
0 - -1 bar
0 - -1 bar
0 - 500 psi
0 - 120 C
0 - 120 C
0 - 120 C
0 - 120 C
0 - 120 C
0 - 30 gpm
0 - 30 gpm
0 - 30 gpm
0 - 20 gpm
0 - 700 psi
0-1100 volts
0 - 200 Kw
0 - 200 Kw
0 - 100 Kw
Gathering Arm Left hand

Gathering Arm Right hand
Bridge Conveyor
Apron Sump (in)
Apron Lift (up)
Rear Jacks (down)
L.H Track (frwd)
R.H Track (frwd)
L.H Track (bkwd)
R.H Track (bkwd)
Return Line Filter
on/off
on/off
on/off
on/off
on/off
on/off
on/off
on/off
on/off
on/off
ok/blocked
ok/blocked
ok/blocked
ok/blocked
New
MK3
Real Digital: -
221
New
New
Derived Variables for use by DEXTERITY

Derived Analogues: -
Required Parameters
Boom Position (X,Y)
Boom Slew & Lift
Boom Slew & Lift
% of Face Cut
Current Cutting Time

Cutter Motor Power
% of Face Cut
P/Pack Motor Run Time
P/Pack Motor Power
M/C Run Time % of Shift
P/Pack Motor Power Run Time

Shift Time
Derived Digital: Machine Utilisation

Machine Cutting
Cutter Motor Power

Boom Position
% of Face Cut
Machine Cutting & Loading
Cutter Motor Power

Boom Position
Gathering Arms
Chain Conveyor
Bridge Conveyor
Machine Loading
P/Pack Motor Power

Cutter Motor Power
Boom Position
Gathering Arms
Chain Conveyor
Bridge Conveyor
Machine Running
P/Pack Motor Power
Machine Stood
P/Pack Motor Power
Machine Operation
Machine Cycles
Number of Faces Cut

222
INTRODUCTION
Monitoring of the environment and coal winning machinery has illustrated the benefits of
remote sensing of underground conditions to British Coal management. Since the start of the
rationalisation of British Coal, reducing costs and increasing productivity per man shift has
become of great importance. Methods of working have had to change so that more faces are
being driven in retreat. To enable retreating faces to be installed and operating in the shortest
possible time gate roadways have to be driven faster and coalface equipment installed quicker.
The attention given to drivages has highlighted the shortfalls in available information on
drivage performance and machine utilisation.
A monitoring system specifically for roadheaders will offer on-board machine displays for
operators and coupled with data transmission to a surface computer, management information.
The Project was based on the British Coal's Intrinsically Safe (IS) computer MACE,
(Multipurpose Automation and Control Equipment) and was to investigate and develop
alternative methods of data collection and instrumentation which overcome the limitations of
existing systems. MACE offers an interface for both analogue and digital transducers and has
the flexibility to add extra transducers in a simple manner.
223
PROGRAMME OF WORK
The general plan of work for the project was as follows:-
1)
Identify and specify the requirements of an on-line monitoring system to provide both
health and performance information in a format suitable for colliery personnel.
2)
Identification & procurement system hardware, transducers, and associated mounting

equipment.
3)
Development of appropriate transducers not currently available to monitor an

identified parameter.
4)
Configuration of system hardware to suit the specification of the on-line parameters.
5)
Specification and design of surface displays and data analysis algorithms.
6)
Surface testing of the complete monitoring system, both hardware and software.
7)
Preparation of machine and trial site at Middletion Mine, Derbyshire.
8)
Assessment of results, analysis and report on the work carried out.

SYSTEM
The successful application of real time monitoring on roadheaders will provide a full analysis
of performance and reliability. This information can be used by the machine operator and
management staff to run machines more efficiently. In order to give optimum performance
and better maintenance scheduling, thus leading to greater machine utilisation, increased
productivity and provide enhanced drivage rates.
225
Previous tunnelling machine monitoring work has indicated that a correctly monitored
roadway drivage machine, with information available to both the underground operators and
surface colliery staff, could provide a number of benefits:
1)
The facility for the operator to be informed of malfunctions in any of the

machines services, and the ability to select operational information such as
cutting head position.
2)
The ability for maintenance staff to access service parameter information to

help with machine diagnostics and the identification of service deterioration.
3)
The facility of storing, analysing and displaying detailed information at the

surface, using the machine to surface data transmission system allowing current
machine utilisation, and all service information to be available on-line.
4)
The recording and presentation of operational and service history to enable

engineering staff to determine impending problems and take some preventative
action.
MONITORING SYSTEM DESCRIPTION
The project identified two main requirements of a roadheader monitoring system for use
within British Coal mines. The ability to present management with reliable on-line data with
respect to the roadheader's health and performance. The project was to develop a complete
system from transducers to the surface information system. The project identifies the user
requirements for the monitoring system, which parameters to monitor and which colliery
personnel are to benefit from the system.
226
Where possible transducers currently available for use within British Coal mines are used. For
parameters without mining compatible transducers, existing commercial transducers were
modified by developing new interface circuits. The project investigated and developed an
'intelligent' interface for a turbine type flow transducer to achieve MACE compatibility. All
analogue transducers were of an 'active' design incorporating signal conditioning within the
sensor.
MACE allows the monitoring system to be operated either as a stand alone underground
health monitoring system, or by including the underground to surface transmission link a
management health and performance monitoring system.
Display facilities are available at the MACE unit mounted on the drivage machine but are
restricted to textural messages, and parameter measurements. Restricting the underground
information to alarm messages and measured values. Data analysis for health monitoring and
machine performance was derived by the surface computer.
SURFACE MONITORING SYSTEM & DATA TRANSMISSION
The usefulness of the monitoring system depends entirely on the information collected and
how it is presented to the relevant personnel. It is important that the surface installation has
the flexibility to present the data in a concise and informative format, and be modified to
meet future requirements.
The 'DEXTERITY' SCADA (Supervisory Control And Data Acquisition) system developed
by Nucleus Software was identified as having the flexibility required by British Coal to
227
provide a good basis for all surface monitoring and control functions for the foreseeable
future. DEXTERITY is designed as an open system offering flexibility, and allows the user
to develop their own style of information system, with the facility for expansion as the system
requires. The data collected from the monitoring system is added to a real-time database
which represents DEXTERITY'S view of the outside world.
The report details the functional specification for the surface algorithms, the specification
being used as a discussion document to generate feedback from management staff. The
functional specification describes how the performance and health data transmitted from the
roadheader was to be displayed to the monitoring system operator. The surface information
detailed in the specification relates to four areas of roadheader monitoring :-
a)
Real-Time Machine Performance;
b)
Historical Machine Performance;
c)
Real-Time Machine Health;
d)
Historical Machine Health;
Underground to surface low speed data transmission systems have been used extensively
within British Coal for environmental monitoring for many years. With the introduction of
steering on shearers, faster transmission systems are now being used. The application of
MACE communication protocol to mobile mining plant such as roadheaders introduces
problems not encountered with static plant.
The report details the use of pilot signal core data transmission, and the testing necessary to
assess the interaction of the data transmission signal and the safe operation of the pilot circuit.
228
To ensure system compatibility data transmission tests were carried out on each of the gate
end boxes currently in use within British coal mines.
The objectives at this stage were to install the complete monitoring system at an underground
trail site and test the systems capabilities. The system was to be fitted to a Anderson
Strathclyde RH1/4 roadheader at Middleton Mine. The mine environment is not subject to the
strict electrical requirements for equipment that British Coal mines are, and therefore allows
prototype equipment to be tested and modified before electrical approval is applied for.
The report details the installation, commissioning and testing of the monitoring system
underground which identified some minor problems in the surface monitoring display
algorithms.
CONCLUSIONS
The whole system was shown to offer a great improvement over previous attempts to monitor
roadheading machines. No problems were experienced within any of the transducers or
machine mounted hardware. The surface equipment and DEXTERITY proved it's flexibility,
and illustrated that given the right data that roadheader and drivage information can be
presented in a clear and concise format.
For the monitoring trial all the displays operated reliably and provided the information to the
specification for the trial application. The flexibility of the DEXTERITY package enables
229
displays to be configured to almost any application and present the information in any format.
Although the trial system was specified for a single boom type roadheader the flexibility the
system offers does not restrict it solely to this type of mobile plant. With some configuration
modifications the system could be adapted for use on twin boom roadheaders and multi boom
drilling machines etc.
Further work on transducer technology for use within British Coal mines could ensure MACE
offers total flexibility in the monitoring of mobile plant.
For the system to be available for use within British Coal mines it must first be certified for
intrinsic safety. This must cover MACE the associated transducers, hardware and pilot core
data transmission system. Once certified the system offers unrivalled facilities in 'on-line'
monitoring and management information for roadway drivages and provides an area of
monitoring which has so far been unavailable within British Coal mines.
230
SYSTEME DE SURVEILLANCE POUR MACHINES DE TRAAGE

ACCORD CECA 7220-B/825
231
INTRODUCTION
La surveillance de l'environnement et du matriel d'abattage du

charbon a montr la direction de British Coal tous les
avantages qu'on pouvait tirer de la dtection distance des
conditions en fond de mine. Depuis le dbut de la politique de
rationalisation suivie par British Coal, la diminution des cots
et l'augmentation de la productivit par poste-homme revtent une
importance cruciale. Les mthodes de travail ont d tre
modifies pour avoir plus de tailles rabattantes. Pour permettre
la prparation et la mise en service de telles tailles dans les
plus brefs dlais, il a fallu tracer les galeries et installer
les engins de tailles plus rapidement. L'attention apporte aux
traages a soulign les insuffisances des informations
disponibles sur la performance des traages et l'utilisation des
machines.
Un
de
de
de
systme de surveillance destin spcifiquement aux machines

traages permettra aux conducteurs d'avoir une visualisation
la machine sur cran embarqu. Il comportera aussi une liaison
transmission donnes l'ordinateur central en surface.
Le projet, bas sur le systme scurit intrinsque MACE

(Multipurpose Automation and Control Equipment- quipement
polyvalent d'automatisation et de contrle) de British Coal,
avait pour but de rechercher et de mettre au point d'autres
mthodes de collecte de donnes et de mesures pour surmonter les
obstacles rencontrs par les systmes existants. MACE a
l'avantage d'tre une interface autant pour les transducteurs
analogiques que numriques, tout en permettant aisment
l'adjonction d'autres transducteurs.
2
PROGRAMME DES TRAVAUX
Le plan gnral des travaux du projet tait conu ainsi :

1
Identifier et dfinir les spcifications d'un systme de

surveillance en ligne afin de fournir des informations sur
l'tat de la machine et ses performances, dans un format
adapt au personnel des houillres.
Identification et acquisition du matriel de systme, des

transducteurs et de l'quipement de fixation connexe.
Mise
au
point
de
transducteurs
non
disponibles
actuellement, convenant la surveillance d'un paramtre
dfini.
Configuration du matriel systme en

spcifications des paramtres en ligne.
Spcification et conception des crans de surface et des

algorithmes d'analyse des donnes.
Essais en surface de l'ensemble du systme de surveillance,

le matriel et le logiciel.
233
fonction
des
Prparation de la machine et essai in-situ la mine de

Middleton dans le Derbyshire.
Evaluation des rsultats, analyse

travaux effectus.
AVANTAGES PREVUS D'UN SYSTEME DE SURVEILLANCE EN LIGNE DE

MACHINE DE TRAAGE
et rapport
sur les
La bonne application de la surveillance en temps rel sur les

machines de traage permettra d'avoir une analyse complte des
performances et de la fiabilit, informations qui permettront aux
conducteurs des engins et la direction de mieux utiliser les
machines. On obtiendra ainsi des performances optimales, des
plannings de maintenance mieux conus, d'o une meilleure
utilisation des machines, une productivit accrue et des vitesses
de creusement amliores.
Les travaux prcdents conduits sur les systmes de surveillance
des tunneliers ont indiqus qu'une machine de traage de galerie
bien surveille, fournissant des informations aux conducteurs en
fond de mine ainsi qu'au personnel de surface, prsenteraient un
certain nombre d'avantages, savoir :
1
La possibilit pour le conducteur d'tre inform sur les

anomalies de fonctionnement de la machine ainsi que celle
de pouvoir choisir des informations oprationnelles, comme
la position de la tte d'abattage par exemple.
La possibilit pour le personnel de maintenance d'avoir

accs aux informations sur les paramtres de service, de
mieux tablir les diagnostics des machines et d'identifier
les dtriorations ventuelles.
La possibilit de stocker, d'analyser et d'afficher des

informations dtailles en surface, grce la liaison de
transmission de donnes machine-surface, sur l'utilisation
actuelle des machines, ainsi que toutes les informations de
service disponibles en ligne.
L'enregistrement
et
la
prsentation
d'historiques
oprationnelles et de service, permettant aux techniciens
de dpister les problmes imminents et de prendre les
mesures prventives ncessaires.
DESCRIPTION DU SYSTEME DE SURVEILLANCE
Le projet a identifi deux fonctions essentielles que devait

avoir un systme de surveillance pour machine de traage dans les
mines de British Coal. Il fallait que le systme soit capable de
prsenter la direction des donnes en ligne fiables concernant
l'tat et la performance de la machine. Le projet devait mettre
au point tout le systme depuis les transducteurs jusqu'au
systme informatique en surface. D'autre part le projet devait
identifier les besoins qu'avait l'usager du systme de
surveillance, les paramtres surveiller et le personnel de
234
houillre qui doit bnficier du systme.

Dans la mesure du possible, c'taient les transducteurs
actuellement utiliss dans les mines de British Coal qui ont
servis. En ce qui concerne les paramtres n'ayant pas de
transducteurs miniers compatibles, on a fait appel des
transducteurs commerciaux, dont les circuits d'interface ont t
adapts. Le projet s'est attach tudier et mettre au point
une interface "intelligente" pour un transducteur dbitmtrique
moulinet afin d'obtenir la compatibilit MACE. Tous les
transducteurs analogiques taient de type "actif", incorporant
la fonction de conditionnement du signal dans le dtecteur.
MACE permet d'utiliser le systme de surveillance comme
dispositif en fond de mine autonome, ou comme systme de
surveillance des performances et d'tat pour la gestion.
L'unit MACE monte sur la machine de traage disposait de
fonctions d'affichage, limites aux messages textuels et aux
valeurs des paramtres. Les informations en fond de mine se
composaient donc exclusivement des messages d'alarmes et des
valeurs mesures tandis que l'analyse des donnes pour la
surveillance d'tat et la performance de machine tait effectue
par l'ordinateur de surface.
5
SYSTEME DE SURVEILLANCE EN SURFACE ET TRANSMISSION DES

DONNEES
L'utilit des systmes de surveillance dpend entirement des

informations recueillies et de la manire dont elles sont
prsentes au personnel concern. Il est important que
l'installation de surface ait toute la souplesse ncessaire pour
prsenter les donnes sous une forme concise et instructive, tout
en ayant une capacit volutive.
C'est le systme 'DEXTERITY' SCADA (Surveillance Contrle et
Acquisition des Donnes), mis au point par Nucleus Software, que
l'on a jug avoir toute la souplesse d'emploi requise par British
Coal, pour remplir toutes les fonctions actuelles et venir en
matire de surveillance et de commande en surface. DEXTERITY est
conu comme un systme ouvert, ayant toute l'adaptabilit
ncessaire pour que l'utilisateur puisse personnaliser le systme
d'information et en augmenter la puissance. Les donnes
recueillies du systme de surveillance sont ajouts une base
de donnes en temps rel qui reprsente la vue que DEXTERITY a
du monde extrieur.
Le rapport dcrit la spcification fonctionnelle des algorithmes
de surface, document qui a servi de discussion avec les
gestionnaires,
pour
recueillir
leurs
observations. La
spcification fonctionnelle explique comment les donnes de
performance et d'tat provenant de la machine de traage devaient
tre affiches l'oprateur du systme de surveillance. Les
informations de surface prises en compte dans la spcification
couvrent quatre domaines de la surveillance des machines de
traage :
235
a) Performance de machine en temps rel.

b) Historique de performance de machine.
c) Etat de machine en temps rel.
d) Historique d'tat de machine.
Depuis d nombreuses annes, les systmes de surveillance du
milieu ambiant dans les mines de British Coal utilisent beaucoup
les systmes de transmission de donnes faible dbit fond de mine
- surface. Grce l'introduction du guidage sur les haveuses,
les systmes de transmission sont maintenant plus rapides. La
mise en oeuvre du protocole de communication MACE sur les engins
miniers mobiles comme les machines de traage ont fait apparatre
des problmes qui n'existaient pas avec les installations
statiques.
Le rapport prsente en dtail l'utilisation de la transmission
de donnes en partie centrale avec signal pilote et les modes
opratoires mises en place pour tester l'interaction du signal
de transmission des donnes et le bon fonctionnement du circuit
pilote.
Pour assurer la compatibilit du systme, les essais de
transmission des donnes ont t conduits sur chacun des coffrets
d'extrmit de taille actuellement utiliss dans les mines de
British Coal.
6
ESSAIS EN FOND DE MINE A MIDDLETON
A ce stade, les objectifs taient d'installer la totalit du

systme de surveillance en fond de mine et d'en tester les
possibilits. C'est sur une machine de traage Anderson
Strathclyde RH1/4 que le systme devait tre mont. La mine de
Middleton, retenue pour ces essais, ne fait pas l'objet des
strictes rglementations lectriques auxquelles les autres mines
de British Coal sont soumises, et c'est pourquoi il est possible
d'y tester le matriel prototype et de le modifier avant qu'une
demande d'homologation lectrique ne soit prsente.
Le rapport prsente les oprations d'installation, de mise en
service et les essais du systme de surveillance en fond de mine,
qui ont permis d'identifier quelques petits problmes au niveau
des algorithmes d'affichage en surface.
7
CONCLUSIONS
Le systme a montr, dans son intgralit, une trs nette

amlioration par rapport aux tentatives prcdentes sur la
surveillance pour les machines de traage. Il n'y a eu aucun
problme ave les transducteurs ni avec le matriel mont sur la
machine. L'quipement de surface et DEXTERITY a prouv son
adaptabilit l'environnement minier, et a montr qu'en lui
fournissant les bonnes donnes, les informations sur le traage
et la machine peuvent tre prsentes sous une forme claire et
concise.
236
Au cours des essais, tous les crans ont fonctionn avec

fiabilit et ont donn les informations qui taient spcifies
par l'essai. L'adaptabilit du progiciel DEXTERITY permet aux
crans d'tre configurs en fonction de n'importe quelle
application et de prsenter les donnes dans n'importe quel
format. Quoique l'essai ft limit une machine de traage une
flche, on peut facilement imaginer que ce systme de
surveillance n'est pas restreint ce type de machine et qu'avec
quelques modifications, il puisse tre adapt aux machines deux
flches, aux machines de creusement multi-flches et autres.
La conduite de travaux d'tude supplmentaires sur la technologie
des transducteurs utiliser dans les mines de British Coal
pourrait procurer au systme MACE une adaptabilit totale dans
la surveillance des engins mobiles.
Avant de pouvoir tre utilis dans les mines de British Coal, le
systme doit faire l'objet d'une certification de scurit
intrinsque, qui doit couvrir MACE, les transducteurs associs,
le matriel et le systme de transmission de donnes en partie
centrale signal pilote. Une fois certifi, le systme offre des
fonctionnalits indites pour la surveillance en ligne et la mise
disposition d'informations gestionnelles sur le traage des
galeries. Il couvre aussi un domaine de surveillance qui
n'existait
pas
jusque-l
dans
les mines
de
British
Coal.
237
BERWACHUNGSSYSTEME FR STRECKENVORTRIEBSMASCHINEN
EGKS-VEREINBARUNG 7220-AB/825
239
1.
EINFHRUNG
Die Klimaberwachung sowie die berwachung von Streckenvortriebsmaschinen

sind Beispiele fr die Vorteile, die das Fernabtasten der Zustnde unter
Tage der Betriebsfhrung von British Coal bringt. Nach Beginn der
wirtschaftlichen Vereinfachung von British Coal wurde die Minderung der
Kosten und die Steigerung der Produktivitt pro Mann und Schicht zu einem
wichtigen Faktor. Die Abbauverfahren muten auf mehr Rckbaustrebe
verndert werden. Um Rckbaustrebe in der kurzmglichsten Zeit in Betrieb
zu nehmen, war es notwendig, Abbaustrecken schneller aufzufahren und die
Strebausrstung schneller zu installieren. Die hohe Abbaugeschwindigkeit
hat besonders den Mangel an genauen Informationen ber Abbauleistung und
Maschineneinsatz hervorgehoben.
Ein besonders fr Streckenvortriebsmaschinen ausgelegtes berwachungssystem
bietet Bordanzeigen fr den Maschinenfhrer sowie Datenbermittlung von
Betriebsfhrungsinformationen an einen Computer ber Tage.
Das Projekt basierte auf dem eigensicheren Computer MACE (Multipurpose
Automation and Control Equipment) von British Coal und sollte alternative
Verfahren fr Datenerfassung und Instrumentenausrstung untersuchen und
entwickeln, um die Begrenzungen der vorhandenen Systeme zu berwinden. MACE
sieht eine Schnittstelle fr analoge und digitale Mewertgeber vor und
besitzt die ntige Flexibilitt, um zustzliche Mewertgeber ohne weiteres
zuzufgen.
2.
ARBEITSPROGRAMM
Das allgemeine Arbeitsprogramm fr das Projekt wurde wie folgt aufgestellt:

1.
Erkennung und Detaillierung der Anforderung eines On-lineberwachungssystems fr die Ausgabe von Gesundheitsschutz- und
Leistungsinformationen in einem fr die Grubenbelegschaft geeigneten
Format.
2.
Spezifikation und Beschaffung von System-Hardware, Mewertgebern und

zugehrigen Montageeinrichtungen.
Entwicklung von derzeit noch nicht lieferbaren Mewertgebern, um die
erkannten Parameter zu berwachen.
3.
241
4.
Konfiguration der System-Hardware unter Bercksichtigung der On-lineParameter.
5.
Aufstellung und Konstruktion der Anzeigen und Datenauswertungsalgorithmen ber Tage.
6.
Prfung des vollstndigen berwachungssystems ber Tage, d.h.

Hardware und Software.
7.
Vorbereitung von Maschine und Versuchsstrecke in der Grube Middleton,

Derbyshire.
8.
Auswertung der Ergebnisse, Analyse und Bericht ber die

durchgefhrten Arbeiten.
3.
VON DEM ON-LINE-BERWACHUNGSSYSTEM DER STRECKENVORTRIEBSMASCHINEN

ERWARTETEN VORTEILE
Der erfolgreiche Einsatz von Echtzeitberwachung auf Streckenvortriebsmaschinen sollte eine vollstndige Auswertung von Leistung und
Betriebssicherheit erlauben. Diese Informationen knnen vom Maschinenfhrer
sowie Geschftsleitung verwendet werden, um die Nutzleistung der Maschinen
zu erhhen. Dies sollte die Maschinenleistung und die planmige Wartung
verbessern und somit zu einer vorteilhaften Ausnutzung der Maschinen,
erhhten Produktivitt und schnelleren Vortriebsgeschwindigkeiten fhren.
berwachungsversuche auf frheren Vortriebsmaschinen lieen erkennen, da
die korrekte berwachung und Informationserstellung an Maschinenfhrer
unter Tage und Grubenbelegschaft ber Tage erhebliche Vorteile bringen
knnte:
1.
Dem Maschinenfhrer knnten smtliche Strungen in den

Betriebsmitteln der Maschine bekanntgegeben werden und weiterhin
knnte er Betriebsinformationen wie zum Beispiel Schrmkopfposition
anwhlen.
2.
Dem Wartungspersonal werden Informationen zur Verfgung gestellt, um

die Maschinendiagnose zu erleichtern und eine Abnahme der
Betriebsfhigkeit zu erkennen.
3.
Abspeicherung, Auswertung und Anzeige von genauen Informationen ber

Tage unter Verwendung eines Datenbermittlungssystems. Auf diese
Weise stehen Daten ber Maschinenausnutzung und weitere
Betriebsinformationen on-line zur Verfgung.
242
4.
Anlegen und Anzeige von Betriebs- und Wartungsarchivdateien, damit

technische Mitarbeiter drohende Schwierigkeiten erkennen und die
ntigen Abhilfemanahmen treffen knnen.
4.
BESCHREIBUNG DES BERWACHUNGSSYSTEMS
Das Projekt erkennt zwei Hauptanforderungen in einem berwachungssystem fr

Streckenvortriebsmaschinen in den Gruben von British Coal: Die Mglichkeit
der Geschftsleitung zuverlssige prozegekoppelte Daten oder
Funktionsfhigkeit und Leistung der Streckenvortriebsmaschine zukommen
zulassen. Das Projekt sollte ein vollstndiges System von den Mewertgebern
bis zur Datenverarbeitungsanlage ber Tage entwickeln. Das Projekt bestimmt
die Benutzeranforderungen an das berwachungssystem, die zu berwachenden
Parameter und diejenigen Bergleute, welche das System ausnutzen sollen.
Wo immer mglich, sollen Mewertgeber verwendet werden, die schon heute in
den Gruben von British Coal zur Verfgung stehen. Wenn fr gewisse
Parameter keine fr den Bergbau geeigneten Mewertgeber zur Verfgung
stehen, sollen handelsbliche Mewertgeber durch die Entwicklung von neuen
Schnittstellen gendert werden. Das Projekt bernahm Untersuchung und
Entwicklung einer "intelligenten" Schnittstelle fr einen Durchflugeber
mit Meturbine, um eine Kompatibilitt mit MACE zu erreichen. Smtliche
analogen Mewertgeber sahen eine "aktive" Schaltung vor mit
Signalaufbereitung innerhalb des Sensors.
MACE machte es mglich, das berwachungssystem entweder als selbstndiges
Gesundheitsberwachungssystem unter Tage zu betreiben oder durch Zufgen
einer Datenbermittlung an bertage-Einrichtungen der Geschftsleitung ein
Gesundheits- und Leistungsberwachungssystem zur Verfgung zu stellen.
Anzeigen stehen fr das auf der Vortriebsmaschine montierte MACE-Gert zur
Verfgung. Diese sind jedoch auf Textmeldungen und Parametermewerte
beschrnkt. Dies begrenzt die unter Tage zur Verfgung stehenden
Informationen auf Alarmmeldungen und Mewerte. Die Datenauswertung zur
berwachung von Gesundheit und Maschinenleistung erfolgt durch den Computer
ber Tage.
243
5.
TAGESBERWACHUNGSSYSTEM UND DATENBERMITTLUNG
Die Ntzlichkeit des berwachungssystems richtet sich nur nach den erfaten
Daten und der Darstellungsart dieser Daten an die infrage kommenden
Mitarbeiter. Wichtig ist eine ausreichende Flexibilitt der Anlage ber
Tage, um die Daten in genauem informativen Format wiederzugeben und eine
Anpassung an zuknftige Anforderungen zu erlauben.
Das von Nucleus Software entwickelte System "DEXTERITY" SCADA
(berwachungskontrolle und Datenanpassung) schien die von British Coal
geforderte Flexibilitt zu besitzen, um eine gute Grundlage fr alle
berwachungs- und Kontrollfunktionen ber Tage in absehbarer Zeit zu
bieten. DEXTERITY wurde als offenes System entwickelt, das Flexibilitt
bietet und dem Benutzer erlaubt, sein eigenes Informationssystem zu
entwickeln sowie nach Bedarf zu erweitern. Die von dem berwachungssystem
erfaten Daten werden in einer Echtzeit-Datenbank abgelegt, welche
DEXTERITY'S Ansicht der Auenwelt entspricht.
Der Bericht enthlt die Einzelheiten des ber Tage verwendeten Algorithmus
als Unterlage fr eine Besprechung, um einen Informationsrckflu von den
Mitgliedern der Geschftsleitung zu erzeugen. Diese Funktionsbeschreibung
umreit die bermittlung der Leistungs- und Gesundheitsdaten von der
Streckenvortriebsmaschine an die Anzeige des Bedieners des
berwachungssystems. Die in der Beschreibung angegebenen Tagesinformationen
sind auf vier Bereiche der Streckenvortriebsmaschinenberwachung bezogen:
a)
Echtzeit-Maschinenleistung;
b)
frherer Verlauf der Maschinenleistung;
c)
Echtzeit-Maschinenfunktionsfhigkeit;
d)
frherer Verlauf der Maschinenfunktionsfhigkeit.
Langsame Datenbermittlungssysteme zwischen unter und ber Tage wurden

schon seit vielen Jahren von British Coal fr die Umweltberwachung
eingesetzt. Durch die Einfhrung von Steuerung von Schrmwalzen werden
jetzt schnellere bermittlungssysteme verwendet. Die Anwendung des MACEbertragungsprotokolls auf mobilen Abbauanlagen wie zum Beispiel
Streckenvortriebsmaschinen macht gewisse Schwierigkeiten, die bei festen
Anlagen nicht vorkommen.
244
Der Bericht beschreibt die Verwendung einer SchlsselzeichenKerndatenbermittlung und die erforderlichen Prfungen, um die
Wechselwirkung zwischen Datenbermittlungssignal und sicherem Betrieb des
Hilfskreises zu bewerten.
Um die Systemkompatibilitt sicherzustellen, wurden Datenbermittlungsprfungen in jeder Strebverteilungsanlage durchgefhrt, die heute in Gruben
von British Coal eingesetzt wird.
6.
VERSUCHE UNTER TAGE IN DER GRUBE MIDDLETON
Diese Phase zielte darauf, ein vollstndiges berwachungssystem unter Tage

einzubauen und dessen Fhigkeit zu prfen. Das System wurde auf einer
Anderson Strathclyde RH1/4 Streckenvortriebsmaschine in der Grube Middleton
montiert. Diese Grube unterliegt nicht den strikten elektrischen
Anforderungen fr Ausrstungsteile wie in anderen britischen Gruben und
erlaubt deshalb die Prfung und nderung der Prototypanlage vor Beantragung
der elektrischen Zulassung.
Der Bericht detailliert Einbau, Inbetriebnahme und Prfung des
berwachungssystems unter Tage und gewisse unbedeutende Schwierigkeiten,
die mit dem Anzeigealgorithmus ber Tage auftraten.
7.
SCHLUSSFOLGERUNGEN
Das gesamte System lie erhebliche Verbesserungen im Vergleich mit frheren

Versuchen bei der berwachung von Streckenvortriebsmaschinen erkennen.
Keine Mewertgeber oder auf der Maschine montierte Hardware fhrte zu
irgendwelchen Problemen. Die Anlage ber Tage und DEXTERITY bewiesen ihre
Flexibilitt und fhrten zu der Folgerung, da bei Vorhandensein der
korrekten Daten Angaben ber Streckenvortriebsmaschine und
Abbaugeschwindigkeit klar und genau angezeigt werden konnten.
Whrend der Versuche arbeiteten alle Anzeigen zuverlssig und erstellten
die von dem Versuch erwarteten Daten. Die Flexibilitt des DEXTERITYProgramms ermglichte eine Konfiguration der Anzeige auf nahezu jeden
Anwendungszweck und eine Darstellung der Informationen in nahezu jedem
Format. Obgleich das Versuchssystem besonders fr eine Vortriebsmaschine
245
mit einem Ausleger konstruiert wurde, besitzt es ausreichende Flexibilitt,

um nicht auf diese Art von Anlagen begrenzt zu sein. Durch gewisse
Konfigurationsnderungen knnte das System fr die Verwendung auf
Vortriebsmaschinen mit Doppel ausi eger sowie Bohrmaschinen mit mehreren
Auslegern erweitert werden.
Eine Erweiterung der Mewertgebertechnik zum Einsatz in Gruben von British
Coal knnte sicherstellen, da MACE eine totale Flexibilitt fr die
berwachung von fahrbaren Anlagen bietet.
Um ein System in den Gruben von British Coal einzusetzen, ist zunchst eine
Bescheinigung der Eigensicherheit notwendig; diese mu die zu MACE
gehrenden Mewertgeber, Hardware und Schlssel zeichenDatenbermittlungssystem erfassen. Nach der Zulassung bietet das System
unerreichte Mglichkeiten fr die Erstellung von berwachungs- und
Managementinformationen fr den Streckenvortrieb und einen Bereich der
berwachung, der bisher in den Gruben von British Coal nicht zur Verfgung
stand.
246
(
The Communities research and development
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Inform the CORDIS unit of your programme Initiatives,
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consult CORDIS for up-to-date information on other programmes relevant to your activities,
inform your programme participants about CORDIS and the importance of their contribution to the
service as well as the benefits which they will derive from it,
contribute to the evolution of CORDIS by sending your comments on the service to the CORDIS
Unit
For more information about contributing to CORDIS,
contact the DG XIII CORDISUnit
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Tel. +(32) 2 299 0464
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ECHO Customer Service
BP 2373
L-1023 Luxembourg
Tel.+(352) 3498 1240
Fax+(352) 3498 1248
If you are already,an ECHO user, please mention your customer
number.
Jf
European Commission
EUR 15204 Mining operations
N. D. Jenkinson
Luxembourg: Office for Official Publications of the European Communities
1997 246 pp. 21.0 29.7 cm
Technical coal research series
ISBN 92-827-8913-6
Price (excluding VAT) in Luxembourg: ECU 41.50
This project is concerned with the application of the TSRE developed multi
purpose automation and control equipment (MACE) for performance and
health monitoring of roadway drivage equipment used in British Coal mines.
The report identifies the requirement of a monitoring system for drivage
machines and details the anticipated benefits to a colliery of installing the
monitoring system.
The report describes the hardware associated with MACE for roadheader
monitoring and details software requirements for the surface computers,
followed by the subsequent underground testing of the complete monitoring
system at Middleton mine.
The report draws overall conclusions and recommendations, and identifies
possible future work in the area of transducer development.
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ISSN 1018-5593

technical coal research

Monitoring systems for roadheaders

Monitoring systems for roadheaders

Cataloguing data can be found at the end of this publication

Luxembourg: Office for Official Publications of the European Communities, 1997

ANTICIPATED BENEFITS OF A ON-LINE ROADHEADER MONITORING

ROADHEADER MONITORING SYSTEM SPECIFICATION & REQUIREMENTS

Identification of Monitored Parameters

Performance and Health Monitoring Functions

Machine Health monitoring parameters for Underground Trial

Multipurpose Automation Control Equipment (MACE)

5.2.1 Pressure and Temperature

5.2.2 Power Transducers

5.2.3 Pressure Switches

5.2.4 Filter Condition Monitoring

5.2.5 Boom Position

5.2.6 Flow Measurement

5.3.2 Underground to Surface Data Transmission Link

Machine to Gateroad Trailing Cable Data Transmission Tests

Machine to Gateroad Trailing Cable Data Transmission Tests

5.4 Surface Monitoring System

5.4.1 DEXTERITY Overview

5.4.2 Surface Hardware for Roadheader Monitoring Trial

SURFACE SOFTWARE & CONFIGURATION

Real-Time Machine Performance Displays

Historical Machine Performance Displays

Real-Time Machine Health Displays

6.3.1 Hydraulic Services

6.3.2 Electrical Services

6.3.3 Water Services

Historical Health Monitoring Display

UNDERGROUND TRIALS AT MIDDLETON MINE

Middleton Mine Site Description

Site preparation and Installation of the Monitoring System

CONCLUSIONS AND RECOMMENDATIONS

Illustration of the Complete Roadheader Monitoring System

MACE Mounted on Roadheader

Boom Position Sensors mounted on Roadheader

'Intelligent' Flow Transducer and Interface Circuit

Current Machine Utilisation Display

Current Boom Position Display

Debris Clearance System Display

Historical Machine Utilisation Display

Illustration of Machine Percentage Utilisation Display

Actual Display of Machine Percentage Utilisation

Machine % Utilisation Multiple Shift Display

Transducer Thermometer Display

Hydraulic Services Display

Illustration of Elecrical Services Display

Typical Water Circuit Display

Transducer Trend Graph Display

RH1/4 Roadheader at Middleton Mine

Pressure Switches Mounted on Roadheader

Pump Supply Monitoring Transducers

Filter Condition Monitoring Sensors

Water Circuit Flow and Pressure Transducer Mounted on Roadheader

Power Transducer, MACE PSU and Ruggedised Modem Mounted on Roadheader

Junction Boxes Mounted on Roadheader

Monitoring System Cabling Details

Full List of Roadheader Parameters

Machine Variables Real and Derived

On-Line Performance & Health Monitoring for Roadway Drivage Machines