1. INCARF Microprocessor Based Autonomous Control System of Longwall Coal Mining Shearer By: - Rajesh P. Barnwal , L.K. Bandyopadhyay, Gautam Banerjee et.al. Council of Scientific & Industrial Research E-mail: r_barnwal@yahoo.com

5. Operation of Shearer Operational Scene of Shearer Operation

8. Experimental Sites Particulars of Longwall Faces Seetalpur Colliery Moonidih Colliery Dhemomain Colliery VK-7 Incline Pathekhera Colliery Seam Hatnal XVI Top Borachak Top Seam Bottom Section Bagdona Panel PH2 MLIV/2 W-9 Panel 3 Panel D Seam Depth (m) 550 380 180 190 100 Seam Inclination (d) 12 0 9.6 0 7.4 0 11.5 0 9.1 0 Ht. of Extraction (m) 1.7 2.1 3.0 2.9 1.55 Comprehensive Strength (Kg/cm 2 ) 308 180 306 360 439 Density of Coal (T/m 3 ) 1.38 1.4 1.4 1.42 1.4

9. Shearer Specifications Specifications of the Shearer Seetalpur Colliery Moonidih Colliery Dhemomain Colliery VK-7 Incline Pathekhera Colliery Make ASL AB –16 ASL AB –16 EICKHOFF EDW 300/380 ASL AM 500 ASL AB -16 Motor Specification 550 V 150 KW 1440 rpm 1100 V 200 KW 1470 rpm 1050 V 380 KW 1470 rpm 1050 V 500 Hp 1470 rpm 550 V 200 KW 1470 rpm Drum Diameter (m) 1.47 1.4 1.6 1.65 1.2 Drum rpm 45 45 45 35 & 45 45 Average web depth (m) 0.4 0.6 0.55 0.4 0.5

10. Continuous Power Recording Fig.: Continuous recording of power at Seetalpur Colliery Haulage Speed: 5.18 m/min. Scale: 0 - 200 Kw Chart Speed: 3 m/hr Fig.: Continuous recording of power at VK7 Colliery. Haulage Speed: 2.5 m/min. Scale: 0 - 400 Kw Chart Speed: 6 m/hr

11. Summary of Observations Name of Colliery Haulage Speed (m/min) Loading Rate (Tons/hr) Average Power (Kw) Peak Power (Kw) Fleeting Power (Kw) Seetalpur PH2 Face 0.91 1.30 3.58 5.18 51.237 73.195 201.568 291.655 46 50 70 78 60 64 100 118 - - 24.0 - Moonidih MLIV/2 Face 0.94 1.37 1.74 99.49 145.00 184.16 49 52 61 74 86 96 - - 24.0 Dhemomain W8 Panel 2.10 2.51 2.70 291.060 347.886 374.220 146 161 167 208 240 240 18.0 - - Singareni VK7 Incl. Top Seam Panel No 3 1.25 2.50 5.00 7.50 123.54 247.08 494.16 741.24 87 152 218 270 128 216 320 320 - 20.0 - - Pathekhera Panel D 0.792 1.829 51.590 119.050 116 184 - - - 16.0

14. System Description T1 -Current Transducer for Cutter Motor T2 -Voltage Transducer for Cutter Motor T3 -Current Transducer for Haulage Motor T4 -Techo Sensor for RPM of Haulage Motor T5 -Sensor for O/p frequency of the Variable Speed AC Drive T6 -Sensor for O/p Voltage of the Variable Speed Drive Block Diagram of the Designed Control System MICROPROCESSOR REGULATED DC VOLTAGE SUPPLY CUTTER MOTOR CUTTING DRUM FIRING & TIMING CIRCUIT VARIABLE SPEED DRIVE DAC DISPLAY UNIT LOAD HAULAGE MOTOR T3 T5 T6 T4 T2 T1 12V 5V -12V 1100 V ADC

15. Block diagram of Laboratory Experimental Setup T1 -Current Transducer for Cutter Motor T2 -Voltage Transducer for Cutter Motor T3 -Current Transducer for Haulage Motor T4 -Techo Sensor for RPM of Haulage Motor T5 -Sensor for O/p frequency of the Variable Speed AC Drive T6 -Sensor for O/p Voltage of the Variable Speed Drive Block Diagram of the Developed Control System MICROPROCESSOR REGULATED DC VOLTAGE SUPPLY COMPUTER PC PRINTER FIRING & TIMING CIRCUIT VARIABLE SPEED DRIVE DISPLAY UNIT LOAD HAULAGE MOTOR T3 T5 T6 T4 12V 5V -12V 440 V ADC DAC PLOTTER

21. Flowchart The Control Algorithm for the Cutting operation of the Shearer (Actual Operation) CS - Control Signal to the Drive  S1 - Small increment in the CS  S2 - Small decrement in the CS SSmin -Minimum Haulage Motor Speed SSmax -Maximum Haulage Motor Speed IHmax -Maximum Haulage Current IH - Haulage Motor Current IC - Cutter Motor Current V - Input Voltage to the Drive W - Input power of the Drive SS - Haulage Motor Speed CSH - Control Signal to stop the haulage motor FLIH -Full load Haulage Motor Current FLIC -Full load Cutter Motor Current IC - Cutter motor current 1 CS = CS +  S1 OUT CS TO DRIVE HAULAGE DELAY INPUT IH, IC, V, W, SS OUTPUT IH, IC, V, W DISPLAY IS IH > FLIH IS IH > IHMAX IS IC < FLIC IS SS < SSMAX OUT CSH NO YES YES YES NO NO CS = CS -  S2 STOP MOTOR YES IS SS < SSMIN STOP MOTOR NO NO YES INPUT CONST. CS,  S1,  S2

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