Technology, Productivity and Information on P&H Mining Equipment Woody Haase, Manager-Electrical Development Western Mining Electrical Association Tucson, November 15, 2001
Where are we coming from? A little over 5 years ago: Analog electronic motion controls Simple PLC systems for logic and sequencing Simple fault message displays Only communications link: Dispatch system to send truck from shovel 11.15.2001 P&H Mining Equipment 2
Today--after Technology Changes: Drives Full microprocessor control on both armature and field, continuous interactive operation for optimal cycling Retrofit applications: between 2 and 6 second cycle time reductions New machines: move 115 tons in fastest available time 11.15.2001 P&H Mining Equipment 3
New Machine Digital Drive Control Cabinet Armature, field, and RPC controls PLC Built-in GUI for troubleshooting PLC and drives 11.15.2001 P&H Mining Equipment 4
Today--after Technology Changes PLCs with extensive machine limit systems and protectives Diagnostics available for temperatures Drive faults diagnostics built-in Color touch-screen operator and maintenance HMI units» on-line help, built-in troubleshooting aids reduce downtime 11.15.2001 P&H Mining Equipment 5
Drive Monitor 11.15.2001 P&H Mining Equipment 6
PLC Equipment PLC processor Appropriate I/O--rack style or Flex Interface to drives Interface to OAP 11.15.2001 P&H Mining Equipment 7
Temperature Display All new motors equipped with four RTDs» Drive End Bearing» Opposite Drive End Bearing» Main Field coil» Interpole 11.15.2001 P&H Mining Equipment 8
Temperature Trending 11.15.2001 P&H Mining Equipment 9
Motion Limits and Boom Protection 11.15.2001 P&H Mining Equipment 10
Integrating Technology Boom Profile Bearing temp. Smart MCC PanelView Smart Lube Dipper Trip Modem Primary Information Centers Smart Brakes PLC Load Weigh System Optional Products OptiDig Digital Drive GUI GPS Position HUB Oil Analysis OAP Computer Power profiling Intuitive Control Material recognition Track Guard Vibration Analysis System modules communicating via Ethernet Touch terminals 11.15.2001 P&H Mining Equipment 11 Electric Mining Shovel shown, similar for Draglines and Blast Hole Drills
Today--after Technology Changes Open Architecture Processor (OAP) for data» adds pre-processing and data collection ability On-board, on-the-fly payload weighing Ability to send data off-board = optional 11.15.2001 P&H Mining Equipment 12
Open Architecture Processor Allows high speed data processing independent of critical machine control Access to other mine systems via ethernet connection 11.15.2001 P&H Mining Equipment 13
Replacing on-off sensors with transducers Allows more flexible response to changing conditions Resistance Temperature Detectors (RTDs) vs. temperature switches Pressure transducers vs. switches for air and lube pressure Resolvers vs. limit switches for position, e.g. Automatic Boom Soft Setdown (ABSS) Transducer vs. no sensor for Lube Level 11.15.2001 P&H Mining Equipment 14
Lube level transducers 11.15.2001 P&H Mining Equipment 15
Transducers generate more data flow Transducers vs. on-off switches» words of data vs. one single bit» trending and histories mean files of words vs. one single bit What do we do with all this data? Storing it and transmitting it both have downsides 11.15.2001 P&H Mining Equipment 16
More Data Digital Drives and additional PLC functions provide increased information when an alarm or fault occurs» on-line diagnostics shorten MTTR, but generate more data Additional functionality to assist productivity, e.g. OptiDig tm stall prevention 11.15.2001 P&H Mining Equipment 17
Future Directions Continued work toward on-line predictive diagnostics (vibration data, oil analysis) More monitoring of machine/operator aspects to balance maximum productivity against increased maintenance, e.g. OptiDig tm,track Guard tm Work on Smart Brakes and Smart Motor Control Centers 11.15.2001 P&H Mining Equipment 18
Future Directions - cont d Work on adaptive controls for drives taking into account :» power system conditions» material changes All of these have data flow implications! 11.15.2001 P&H Mining Equipment 19
i2t: Remote Communications Information MINE OFFICE Machine Data MACHINE 11.15.2001 P&H Mining Equipment 20
Link to Server Server 11.15.2001 P&H Mining Equipment 21
i2t: Integrating Information Linking information - - i2t Remote Communications Internal to machine Machine to Mine Office Mine Office to internal LAN, P&H,... Common platform for: Multiple options (LWS, Remote Communications,...) Universal solution to Shovels, Draglines, Drills 11.15.2001 P&H Mining Equipment 22
How do we move data off-board? Push vs. Pull P&H i2t approach has been to pull data off-board from on-board Only transmit specifically requested data Requires person at off-board side to request data Requires separate radio channels due to bandwidth/size of data stream 11.15.2001 P&H Mining Equipment 23
Push vs. Pull (continued) Why not push commonly desired data into an off-board database?» Requires on-board pre-processing» requires a communication pipeline with capacity Pull makes sense when dealing with long streams of data» example: motor currents and voltages, temperature logs, fault information 11.15.2001 P&H Mining Equipment 24
Mining Information for Multiple Users Management Production Mine Planning Maintenance P&H (MinePro, Engineering, Service, Management, ) 11.15.2001 P&H Mining Equipment 25
Information Challenges Mobile equipment - stationary office Global communications disparities Remote locations Insufficient qualified personnel Mines do not want several different communications systems--one network should service all pit equipment 11.15.2001 P&H Mining Equipment 26
Collaboration Need Industry consensus on data file format. Mine-specific requirements identified and variations minimized. Trust. 11.15.2001 P&H Mining Equipment 27
Conclusion P&H wants to be part of the solution. In-pit radio systems are not a P&H core competency. i2t Products are a start toward better information management. The Industry (Miners, OEM s, 3rd Parties) need to collaborate toward mine-wide integration. Mines, however, need to be the drivers! Tell us what YOU want. 11.15.2001 P&H Mining Equipment 28