PDF CAT VShieldSingle – Visualization of face automation Operating & Maintenance Manual EM031189

Media-ID: EM031189-00-EN Doc.-No.: 1999 001 196 AN 00-01 Mar. 2022

Operating and Maintenance Manual VShieldSingle – Visualization of face automation

SAFETY.CAT.COM

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CAT, CATERPILLAR, THEIR RESPECTIVE LOGOS, ”CATERPILLAR YELLOW“ AND THE “POWER EDGE” TRADEDRESS, AS WELL AS CORPORATE AND PRODUCT IDENTITY USED HEREIN, ARE TRADEMARKS OF CATERPILLAR AND MAY NOT BE USED WITHOUT PERMISSION.

Table of Contents

Table of Contents 1 About This Manual ...................................................................................... 5 1.1 Before Starting Work ............................................................................ 5 1.2 Signs and Symbols Used...................................................................... 5 2 Safety............................................................................................................ 8 2.1 Intended Use ........................................................................................ 8 2.2 Pre-requisites For Operation ................................................................ 8 2.3 Basic Hazards....................................................................................... 9 3 Installation.................................................................................................. 10 3.1 Minimum Requirements...................................................................... 10

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3.2 Recommended Requirements ............................................................ 10 3.3 Installation of the Software (Visualisation Only) ................................. 11 3.4 Installation of the Software (Visualisation & API)................................ 12 4 User Administration .................................................................................. 14 5 Operation - Visualisation .......................................................................... 15 5.1 Introduction ......................................................................................... 15 5.2 User Interface ..................................................................................... 16 5.3 Sensor Values .................................................................................... 20 5.4 Sensor States ..................................................................................... 20 5.5 System Warnings................................................................................ 21 5.6 System Errors ..................................................................................... 22 5.7 PPD Tags ........................................................................................... 23 6 Operation - API .......................................................................................... 24 6.1 Introduction ......................................................................................... 24 6.2 Enabling from PMC-R/PMC-R 2.0 ...................................................... 25 6.3 Shearer Safety Zone........................................................................... 26 6.4 Shearer Remote Safety Zone ............................................................. 27 6.5 Single Shield Commands ................................................................... 28 6.6 Automatic Function Commands.......................................................... 35 6.7 SRB Commands ................................................................................. 40 6.8 Dump Valve Commands..................................................................... 42 6.9 Anti-collision Override Command ....................................................... 42 6.10 Stacked Commands ........................................................................... 43 6.11 User Log In/Logout ............................................................................. 44 6.11.1 Session Expiry ......................................................................... 47 6.12 Controls Panel .................................................................................... 48 6.13 Controls/Single Panel ......................................................................... 49 6.13.1 Shield Selection ....................................................................... 49 6.13.2 Operating Time Controls.......................................................... 50 6.13.3 On/Off Controls ........................................................................ 50 6.13.4 Send Command ....................................................................... 51

VShieldSingle – Visualization of face automation

Table of Contents

6.13.5 Command Response ............................................................... 51 6.13.6 Changing Shield Selection....................................................... 51 6.14 Controls/Auto Panel............................................................................ 52 6.14.1 Start/End Shield Selection ....................................................... 53 6.14.2 ASQ Shield Selection............................................................... 54 6.14.3 On/Off Control.......................................................................... 54 6.14.4 Start/End Control ..................................................................... 54 6.14.5 Start/End with Target Control................................................... 54 6.14.6 ASQ Control............................................................................. 55 6.14.7 Send Command ....................................................................... 55 6.14.8 Command Response ............................................................... 55

6.16 Controls/Dump Panel.......................................................................... 58 6.16.1 Shield Selection ....................................................................... 61 6.16.2 Dump Valve Control................................................................. 61 6.16.3 Send Command ....................................................................... 61 6.16.4 Command Response ............................................................... 62 6.17 Stop Button/Stop Key ......................................................................... 62 6.18 User Administration ............................................................................ 62 7 Maintenance............................................................................................... 63 8 Reference Information .............................................................................. 64 9 Shield Types .............................................................................................. 65 10 Shield Config ............................................................................................. 66 11 Appendix .................................................................................................... 67

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6.15 Controls/SRB Panel............................................................................ 56 6.15.1 Shield Selection ....................................................................... 58 6.15.2 SRB Controls ........................................................................... 58 6.15.3 Send Command ....................................................................... 58 6.15.4 Command Response ............................................................... 58

About This Manual

1

Before Starting Work

1 About This Manual This chapter contains important information which will simplify work with this manual for you. In addition, it contains information about the structure of the manual and the characters and symbols used.

1.1 Before Starting Work

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Using a manual that is not written for the equipment at hand can result in a safety hazard for yourself and others. Make sure the information on the equipment complies with that given in the manual. The manual must be accessible at all times to all persons working on or with the equipment. There should, if possible, always be a manual for the equipment available at the place of operation.

Request a new manual immediately if the current manual is no longer complete or has become illegible.

This operating manual is intended for all persons that are required to use or configure the VShieldSingle PC application.

This includes persons who: Install and uninstall the program Use the program Perform troubleshooting and maintenance work.

This operating manual is intended to facilitate the safe and efficient handling of the program. The responsible operating, setup and maintenance personal must read, understand and comply with this manual. The information contained in this operating manual will avoid misuse of the program and provide trouble free operation.

1.2 Signs and Symbols Used The following signal words are used for safety instructions in this operating manual.

DANGER WARNING CAUTION All safety instructions have the following structure: 1. Symbol next to the text passage 2. First line Signal word (DANGER, WARNING, CAUTION) 3. Type of hazard 4. Instruction for avoiding hazard

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1

About This Manual Signs and Symbols Used

DANGER

Danger!

Points in the text marked with this symbol indicate immediate danger. Possible consequences are very serious injury or even death.

Example: Danger!

Suspended loads, falling load Possible consequences are very serious injury or even death.

Never stand under unsecured or suspended loads! Always use means of attachment which are the sufficient size and in perfect operating condition.

WARNING

Points in text marked with this symbol draw attention to a danger which, if ignored, could lead to serious injury or death.

Example: Warning!

Missing safety equipment on rotating machine parts Possible consequences are very serious injury or even death caused by being pulled in or caught. Never operate the conveyor system without safety equipment on rotating machine parts.

Check the safety equipment of all safety equipment regularly.

CAUTION

Caution!

Points in text marked with this symbol draw attention to a danger which, if ignored could lead to injuries and/or damage to machinery.

Example: Caution!

Incorrect values for parameters can cause damage to the equipment.

You need to know exactly what the parameters mean before you make changes to them. Consult the operating manual to find out the meaning of the parameters.

IMPORTANT

This is another symbol which may be used to provide additional clarification or for additional information on exceptional circumstances These instructions have the following structure Information symbol next to the text passage First line: single word (Important) Following lines: description of the circumstance or additional information Important!

Text passages which are marked with this symbol provide you with useful tips and instructions in order to facilitate your work.

This instruction is not to be understood as a warning.

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Warning!

About This Manual Signs and Symbols Used

1

Example: Important!

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See documentation of the PMC-R for further information about incremental plowing.

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2

Safety Intended Use

2 Safety This chapter provides vital safety information, pay special attention to this chapter. The safety instructions and rules will help avoid hazardous situations and to perform the necessary work as safely as possible.

2.1 Intended Use The intended use is to provide visualisation of events and sensor data on the PMC-R/PMC-R 2.0 Shield system, the program can be configured to control the PMC-R/PMC-R 2.0 Shield system remotely but does not provide the ability to alter parameters.

Visualization of sensor data for each shield in the PMC-R/PMC-R 2.0 Shield system Remote Control of Shield System via REST API Interface The program does not provide the ability to change parameters in the PMCR/PMC-R 2.0 Shield system

2.2 Pre-requisites For Operation The VShieldSingle PC application provides the user with visualization of the PMC-R Shield system for use as feedback for control, therefore the user of this program should first be trained in the operation and maintenance of the intended PMC-R Shield system.

The program sources its data from the associated VDataSrv program so it is necessary for this application to be installed, configured and verified by a competent person prior to installing of the VShieldSingle Application.

The program can additionally provide a login to the VShield REST API server and API commands can be sent for remote operation of the Shield system. The API interface relies on the correct installation and setup of numerous programs including VShield, VDataSrv, VDataSrvDB, VUserService and VUserManagement so it is necessary for these applications to be installed, configured and verified by a competent person prior to installing the VShieldSingle application.

The VShieldSingle application must be configured correctly for each mine installation as there are variations between shield types and/or API commands for each installation. Configuration of the VShieldSingle application should be configured and verified by a competent person prior to use.

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Visualization of events for each shield in the PMC-R/PMC-R 2.0 Shield system

Safety Basic Hazards

2

2.3 Basic Hazards The VShieldSingle application can be configured to be used in two ways, as visualisation only of the PMC-R Shield system or as visualisation and the API Client for remote control of the PMC-R Shield system, the hazards presented by the visualisation and API Client components will be discussed separately as they present different hazards to the user.

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Visualisation In this mode of operation VShieldSingle PC application provides the user with only visualisation of the PMC-R Shield system and does not provide control of the PMC-R Shield system or the ability to change parameters, the hazards are therefore limited to the data being correct when used as feedback for control when operating the PMC-R Shield system by other means. Incorrectly supplied data to the program may provide the operator with a false representation of the shields operating state causing Shields to be operated dangerously with the possibly of equipment damage.

Caution!

Incorrect configuration files Incorrect configuration of the VDataSrv PC application may provide incorrect information to the user resulting in damage to the equipment. Please ensure that VDataSrv is installed and configured correctly by a competent person prior to use.

Caution!

Incorrect configuration files Incorrect configuration of the VShieldSingle PC application may provide incorrect information to the user resulting in damage to the equipment. Please ensure that VShieldSingle is installed and configured correctly by a competent person prior to use.

API Client When the API Client has been configured for use this enables a logged in user to remotely control the PMC-R Shield system using commands within the program. This means Shields can be operated without the VShieldSingle user having line of sight of the machine they are controlling.

Danger!

Non-line of sight operation of machinery Possible consequences are very serious injury or even death. Please ensure thorough operation risk assessments are completed to mitigate the risk of persons being injured as a result of the API Client operating shields in the vicinity of people.

Without proper administrative controls unauthorised users may gain access to the API Client controls.

Danger!

Unauthorised users Possible consequences are very serious injury or even death. Implement correct administrative controls to ensure only authorised users can gain access to the API Client controls.

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3

Installation Minimum Requirements

3 Installation The following system requirements must be fulfilled before installation of the installation of the visualisation program on a PC above ground.

3.1 Minimum Requirements Minimum requirements for the operation: Microsoft Windows©7 or Windows©10 32-bit or 64-bit Intel Core i5 or compatible 4-core processor with 3 GHz CPU speed Graphics card with support of Direct C10.0 hardware acceleration OpenGL ICD (ZBuffer, 24-bit) 4 GB RAM Mini-tower or desktop housing Network connection USB CD-ROM

3.2 Recommended Requirements Recommended requirements for operation: Microsoft Windows©10 64-Bit Intel Core i7 or compatible with 4 or more core processor and 3GHz or more CPU speed Graphics card with support of Direct C10.0 hardware acceleration OpenGL ICD (ZBuffer, 24-bit) 8 GB RAM Greater than 100MB available storage space Mini-tower or desktop housing Network connection USB CD-ROM

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At least 100MB of available storage space on the hard drive.

Installation

3

Installation of the Software (Visualisation Only)

3.3 Installation of the Software (Visualisation Only) Installation of VDataSrv The following steps are intended as a guide only and the installation should be completed by a competent person: 1. Install VDataSrv PC application.

2. Configure the VDataSrv program startup file ensuring the UDP server is activated.

3. Configure the VDataSrv tag information file.

4. Run the program and check UPD server is running and the tag information is correct.

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Caution!

Incorrect configuration files.

Incorrect configuration of the VDataSrv PC application may provide incorrect information to the user resulting in damage to the equipment. Please ensure that VDataSrv is installed and configured correctly by a competent person prior to use.

Installation of VShieldSingle The following steps are intended as a guide only and the installation should be completed by a competent person: 1. Install the VShieldSingle PC application.

2. Configure the VShieldSingle startup file for the PMC-R Shield system in operation, ensure shield types and sensor scaling are configured correctly.

Also ensure the UDP interface is configured correctly for the instance of VDataSrv being used.

3. Run the program and check the program connects to the UDP interface, check the data for each shield type is being sourced correctly from VDataSrv UPD interface.

Caution!

Incorrect configuration files.

Incorrect configuration of the VShieldSingle PC application may provide incorrect information to the user resulting in damage to the equipment. Please ensure that VShieldSingle is installed and configured correctly by a competent person prior to use.

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3

Installation Installation of the Software (Visualisation & API)

3.4 Installation of the Software (Visualisation & API) Installation of VDataSrv The following steps are intended as a guide only and the installation should be completed by a competent person: 1. Install VDataSrv PC application.

2. Configure the VDataSrv program startup file ensuring the UDP server is activated.

3. Configure the VDataSrv tag information file.

4. Run the program and check UPD server is running and the tag information is correct.

Incorrect configuration files.

Incorrect configuration of the VDataSrv PC application may provide incorrect information to the user resulting in damage to the equipment. Please ensure that VDataSrv is installed and configured correctly by a competent person prior to use.

Installation of VDataSrvDB The following steps are intended as a guide only and the installation should be completed by a competent person: 1. Install VDataSrvDB database as a pre-requisite for storing and retrieving user login information.

Installation of VUserService The following steps are intended as a guide only and the installation should be completed by a competent person: 1. Install VUserService windows service for connection to the VDataSrvDB database.

Installation of UserManagement The following steps are intended as a guide only and the installation should be completed by a competent person: 1. Install VUserManagement PC application.

2. Use the application to create usernames that will be used to login for use of the REST API interface.

Installation of VShield The following steps are intended as a guide only and the installation should be completed by a competent person: 1. VShield PC application should be already installed on the system for visualisation of the shields but also contains the REST API server.

2. Ensure the VUserMangement is enabled in the VShield configuration and a connection to the database is healthy.

3. Ensure the REST API server is enabled in the VShield configuration and the connection with the REST API server is healthy.

Installation of VShieldSingle The following steps are intended as a guide only and the installation should be completed by a competent person: 1. Install the VShieldSingle PC application.

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Caution!

Installation

3

Installation of the Software (Visualisation & API)

2. Configure the VShieldSingle startup file for the PMC-R Shield system in operation, ensure shield types and sensor scaling are configured correctly.

Also ensure the UDP interface is configured correctly for the instance of VDataSrv being used.

3. Configure the VShieldSingle startup file for the connection to the VShield REST API server, ensure correct API commands are configured correctly for the desired mine site.

4. Run the program and check the program connects to the UDP interface, check the data for each shield type is being sourced correctly from VDataSrv UPD interface.

5. Check the program can login to the VShield REST API server, check the correct API commands configured for the specific application.

Caution!

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Incorrect configuration files.

Incorrect configuration of the VShieldSingle PC application may provide incorrect information to the user resulting in damage to the equipment. Please ensure that VShieldSingle is installed and configured correctly by a competent person prior to use.

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4

User Administration

4 User Administration

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Access to program installation and configuration files should be controlled via the system administrator to prevent unauthorised access.

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Operation - Visualisation Introduction

5

5 Operation - Visualisation This chapter will introduce the program, outline the system architecture and provide the user with the necessary information to understand the program operation.

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5.1 Introduction The VShieldSingle program was developed to visualise any Shield’s sensor information and selected events and errors in a single, easily readable view with the purpose of operating Shields remotely on a Longwall. The sensor information provides the remote operator with clear picture of any Shield’s operating state allowing them to make decisions on how to remotely operate the Shield via the PMC-R shield system. The event and error indication is a limited set selected to be useful to the remote operator without crowding the screen with masses of information. It is recommended for mine sites to refer to the VShield application for the full list of events and errors on the PMC-R Shield system.

The VShieldSingle application operates using data originating from the PMC-R Shield system. The data is sent from the PMC-R server underground to a PMCP or I.S. Ethernet Switch via a serial connection. The I.S. Ethernet switch transports the data over the mines network typically first to an underground PC running an instance of the VShield PC application. This underground VShield instance must then forward the information to a surface PC also running an instance of the VShield application. On the Surface PC an instance of the VDataSrv PC application is required, the VDataSrv application collects the data from VShield and allows it to be distributed in different formats, for instance the VShieldSingle application using the UDP data format. However other programs may make use other formats offered such as OPC or EIP. Finally, the VShieldSingle application collects the data from the VDataSrv UDP interface which it uses to visualise each Shield on the Longwall.

Fig. 1: System Architecture

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5

Operation - Visualisation User Interface

5.2 User Interface The diagram below provides an overview of the main controls and indications of the program, the text following correlates to the diagram explaining each one of the indexed features.

Fig. 2: User Interface Overview

2

1.10 1.1 1.2 1.3

1.4

1.5 1.6 1.7 1.8 1.9

1.12 1.11

3.1

3.2

7

8

5

4

6

1 - Automatic Function Indications 1.1- Auto Sequence (ASQ) Function Indication

Solid White = ASQ function active on the Shield Flashing White = ASQ function waiting on the Shield Grey = ASQ function inactive on the Shield 1.2 - Batch Advance Function Indication

Solid White = Batch Advance function active on the Shield Flashing White = Batch Advance function waiting on the Shield Grey = Batch Advance function inactive the Shield 1.3 – Bankpush Function Indication

Solid White = Bankpush function active on the Shield Flashing White = Bankpush function waiting on the Shield Grey = Bankpush function inactive the Shield

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Operation - Visualisation User Interface

5

1.4 – Conveyor Pullback Function Indication

Solid White = Conveyor Pullback function active on the Shield Flashing White = Conveyor Pullback function waiting on the Shield Grey = Conveyor Pullback function inactive the Shield 1.5 – Rear Conveyor Pull Function Indication

Solid White = Rear Conveyor Pull function active on the Shield Flashing White = Rear Conveyor Pull function waiting on the Shield Grey = Rear Conveyor Pull function inactive the Shield Media-ID: EM031189-00-EN / Caterpillar Global Mining Europe GmbH 2022 ©

1.6 – Positive Set Automatic (PSA) Function Indication

Solid White = PSA function active on the Shield Flashing White = PSA function waiting on the Shield Grey = PSA function inactive the Shield 1.7 – Bank Flipper Function Indication

Solid White = Bank Flipper function active on the Shield Flashing White = Bank Flipper function waiting on the Shield Grey = Bank Flipper function inactive the Shield 1.8 – Auto TCC (Top Coal Caving) Function Indication

Solid White = Auto TCC function active on the Shield Flashing White = Auto TCC function waiting on the Shield Grey = Auto TCC function inactive the Shield 1.9 – Shearer Running Batch (SRB) Function Indication

Solid White = SRB active on the Shield Flashing White = SRB waiting on the Shield Grey = SRB inactive the Shield 1.10 - Front Collision Warning/Error

See System Warnings and System Errors

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Operation - Visualisation User Interface

1.11 - Rear Collision Warning/Error

See System Warnings and System Errors 1.12 - PPD Tag Indication

See System Warnings and System Errors

2 - PMC-R Mode Idle - No adjacent or remote control is active on the Shield.

Slave -The Shield is being controlled from a Master PMC-R using adjacent or remote control.

EStop - The Red Stop Button is pressed on the Shield Locked - The Black Lockout Button is pressed on the Shield Soft Locked - A Black Lockout Button is pressed on one of the neighbouring Shields Manual Disabled – Indicates that manual functions are not possible on the Shield.

Shield Cycle Times 3.1 - ASQ Cycle Time - Shows the time taken for last successful ASQ function on the Shield 3.2 - TCC Cycle Time - Shows the time taken for the last successful TCC function on the Shield.

Important!

The TCC Cycle Time will not populate data on Shields that do not perform the Top Coal Caving (TCC) functionality. This field is configurable and can be hidden from view if desired.

4 – Shield Selection Text This field identifies the current shield that is shown in the Shield Display Window, clicking on this field, typing the shield number and pressing the enter key will change the Shield Display Window to the typed shield number.

Important!

The Shield Manual Selection Mode must be selected to enable shield selection via typing the shield number and pressing enter. When the Shield Auto Selection Mode is enabled the Shield selection Text will be read only.

5 – Shield Face Wide Selection Bar Each square in this bar represents a Shield on the longwall, clicking on a square will bring up the selected Shield number in the Shield Display Window.

Important!

The Shield Manual Selection Mode must be active to enable the Shield Face Wide Selection Bar

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Master - The Shield is being used to control a Slave PMC-R using adjacent or remote control.

Operation - Visualisation User Interface

5

6 – Shield Focused Selection Bar After selecting a shield in the Shield Face Wide Bar, the Shield Focused Selection Bar allows the selection of 5 shields on either side of the selection made in the Shield Face Wide Selection Bar. Larger buttons with shield number identification are afforded in the Shield Focused Selection Bar for identification of the selected shield and for moving easily between shields around the selected shield position.

Important!

The Shield Manual Selection Mode must be active to enable the Shield Focused Selection Bar

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7 – Shield Manual Selection Mode Clicking this icon enables the Shield Manual Selection Mode and disables the Shield Auto Selection Mode. The shield shown in the Shield Display Window is determined by the Shield Face Wide Selection Bar, the Shield Focused Selection Bar or the Shield Selection Text. Shields will not automatically be shown when selected from the Remote SCU PMC-R.

8 – Shield Auto Selection Mode Clicking this icon enables the Shield Auto Selection Mode and disables the Shield Manual Selection Mode. The shield shown in the Shield Display Window is determined by being selected from the Remote SCU PMC-R. The Shield Face Wide Selection Bar, Shield Focused Selection Bar and the Shield Selection Text cannot be used to change the Shield shown in the Shield Display Window.

9 – Shield Display Window This window shows the sensor values, sensor states and system events, warnings and errors present on the selected shield. The shield image shown in this window reflects the geometry of the shield type on the Longwall.

Caution!

Shield type shown incorrect Shield pictured does not accurately reflect the geometry and sensor configuration of that on the Longwall.

Feedback for shield control compromised. Please check that the VShieldSingle configuration is correct before controlling shields on the Longwall.

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5

Operation - Visualisation Sensor Values

5.3 Sensor Values Sensor configuration varies between different shield types but any shield type will include a combination of the following sensors present in the system:

Pressure Transducers Right Leg - Right Leg Pressure (0-600 Bar) Left Leg - Left Leg Pressure (0-600 Bar) Rear Leg - Rear Leg Pressure (0-600 Bar) F – Right Leg – Front Right Leg Pressure (0-600 Bar) F - Left Leg – Front Left Leg Pressure (0-600 Bar)

Reed Rods Flipper – Flipper Reed Rod (0 -100%) Forepole – Forepole Reed Rod (0-100%) Caving Door - Caving Shield Door Reed Rod (0-100%) Caving Slide – Caving Shield Slide Reed Rod (0-100%)

3D Tilt Inclinometer H1 – Canopy tip height to floor (mm) H2 – Centre of the canopy leg cylinder pin to floor (mm) H3 – Centre of the canopy pin to floor(mm) H4 – Caving shield slide tip to floor (mm) H5 – Centre of the rear canopy pin to floor (mm). Note: Selected 3 Leg Shields Only Base –The face advance angle of the Shield or the Alpha1 angle (Degrees) Canopy – The canopy angle or the difference between the Base (Alpha1) angle and the Goaf (Beta) angle (Degrees) Compensation - The calculated angle between the Canopy and the Goaf (Beta) for protection of the shield compensation cylinder (Degrees)

5.4 Sensor States Healthy A healthy sensor is indicated by a white text, the sensor value shown can be trusted as being correct when shown as healthy.

Fig. 3: Healthy Sensor Example

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DA Stroke - DA Ram Reed Rod (0 – 100%)

Operation - Visualisation System Warnings

5

Ignored An ignored sensor is indicated by an white text with blue cross hatched background, the sensor value cannot be trusted when shown as ignored as a problem may exist with the sensor or operators have ignored the sensor due to unexpected operating conditions.

Fig. 4: Ignored Sensor Example

Faulty

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A faulty sensor is indicated by grey cross hatched background and the ‘***’ symbol representing the sensor value, the sensor is shown as faulty when the sensor is disconnected, out of range or when no data is being received VDataSrv UDP interface.

Caution!

No data shown for sensor.

A sensor may show as faulty if no data is being received from the VDataSrv program as opposed to actually being faulty. Please ensure VDataSrv configuration is correct before controlling shields on the Longwall.

Fig. 5: Faulty Sensor Example

5.5 System Warnings High level Warning A sensor value that has exceeded the system high level warning limit will be indicated with white text, orange background and the ‘↑’ symbol. In this condition some functionality may be inhibited however operations should be allowed to continue.

Fig. 6: High Level Warning Example

Low level Warning A sensor value that falls below the system low level warning limit will be indicated with white text, orange background and the ‘↓’ symbol. In this condition some functionality may be inhibited however operations should be allowed to continue.

Fig. 7: Low level Warning Example

Front Collision Pre-warning A front collision pre-warning is indicated by message box positioned top of the screen at the front of the shield image. The orange and white message box front collision pre-warning indicates that a collision between the shield and the

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5

Operation - Visualisation System Errors

Shearer is likely to occur if operation continues. Shearer speed and arm movement may be restricted as well lowering, tip town, advance and flipper functions on the shield.

Fig. 8: Front Collision Pre-warning

Rear Collision Pre-warning

Fig. 9: Rear Collision Pre-warning Indication

5.6 System Errors High level Error A sensor value that has exceeded the system high level error limit will be indicated with a red box, white text and the ‘↑’ symbol, generally in this condition all operations are stopped and not allowed to continue until the error is cleared.

Fig. 10: High Level Error Example

Low level Error A sensor value that falls below the system low level error limit will be indicated with a red box, white text and the ‘↓’ symbol, generally in this condition all operations are stopped and not allowed to continue until the error is cleared.

Fig. 11: Low Level Error Example

Front Collision Warning A front collision warning is indicated by message box positioned top of the screen at the front of the shield image. The red & white message box front collision warning indicates that a collision between the shield and the Shearer has occurred or is imminent, generally in this condition all operations are stopped and not allowed to continue until the collision warning is cleared.

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A rear collision pre-warning is indicated by message box positioned top of the screen at the rear of the shield image. The orange and white message box rear collision pre-warning indicates that a collision is likely between the shield and the rear AFC if operations continue. The shield caving door and caving slide functions may be restricted in this condition.

Operation - Visualisation PPD Tags

5

Rear Collision Warning A rear collision warning is indicated by message box positioned top of the screen at the rear of the shield image. The red & white message box rear collision warning indicates that a collision has occurred or is imminent between the shield and the rear AFC, generally in this condition all operations are stopped and not allowed to continue until the collision warning is cleared.

5.7 PPD Tags

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Some PMC-R Shield systems are fitted with a personal proximity detection (PPD) system, a tag is carried with an operator on the Longwall and shields are fitted with tag detectors to identify the position of the operator and take appropriate control measures.

Tag In Shield When a PPD tag is detected in the shield the “Tag in Shield” red message box will appear in the top of screen above the shield image. This indicates that a person has been detected on the shield and PPD control measures may be in effect.

Tag In Zone When a PPD tag is detected on a shield a PPD protection zone is setup around the shield where the tag was detected. The ‘Tag in Zone’ orange message box will appear in the top of screen above the shield image when the shield forms part of the PPD protection zone and PPD control measures may be in effect.

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6

Operation - API Introduction

6 Operation - API This chapter will introduce the API extension to the VShieldSingle program, outline the additional system components required and provide the user with the necessary information to understand the operation of the API related features.

As an extension to the visualization component of the VShieldSingle program it can be used to remotely control the Shield System using the inbuilt API (Application Programming Interface) Client. This involves the user logging in to the API Client with username and password allowing them access to collections of commands for controlling the Shied system. The API Client sends all commands directly to the API Server which is inbuilt into the VShield program, the server authenticates user and password information and forwards the commands to the PMC-R/PMC-R 2.0 system which makes the final decision to action the requested command or not. The API Server will always provide a response to the command issued by the client whether the PMC-R / PMC-R 2.0 system executed it or not and VShieldSingle will show this response in its display.

To access the VShieldSingle API Client features a user must first obtain log details, this is done by users being created using the VUserManagement PC application. Login details are created and stored in the VDataSrvDB database. When users Login to the API Client they must enter their username and password that will be authenticated against those stored in the database.

Not only the login, in fact all commands to the API Server are authenticated using username and password details. The API Server authenticates the command by communicating to the VUserService program which provides access to the database to retrieve and authenticate the user details that were provided.

This is done to ensure only verified users are operating the Shield system, commands will not be issued to the PMC-R/PMC-R 2.0 system if authentication fails.

When utilising the API Client for remotely controlling the Shield System the Remote PMC-R underground is optional, the SRC (Surface Remote Control) Master can be omitted from the system and the Remote PMC-R no longer performs

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6.1 Introduction

Operation - API Enabling from PMC-R/PMC-R 2.0

6

the SRC Slave functionality. For PMC-R 2.0 systems only the API Client will be provided for remote control and the SRC Master/Slave configuration is not utilized.

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Fig. 12: System Architecture visualization and REST API Server/Client

6.2 Enabling from PMC-R/PMC-R 2.0 In the PMC-R/PMC-R 2.0 Remote Control menu the global parameter Remote Access determines whether Remote Control Operation from the API Client is enabled or disabled. This is a Level 4 password protected parameter.

When Remote Access=0 Remote Control Operation from the API Client is disabled.

When Remote Access=1 Remote Control Operation from the API Client is enabled.

Each PMC-R also has a local value parameter remote_SCU, this enables or disables all operations on the local shield that are initiated from the API Client.

This is a Level 1 password protected parameter, it can be changed by operators if they feel shields should only be moved from Adjacent Control or Adjacent Remote Control. It will not prevent From-To group functions initiated from a Face SCU operating or any other automatic operations, there are other local parameters that enable and disable the various automatic functions.

When remote_SCU=ON all operations from the API Client are enabled on the local shield.

When remote_SCU = OFF all operations from the API Client are disabled on the local shield.

Note:The global parameter Remote_Adj controls enabling or disabling Remote Adjacent Control only and has no link to the operation of the API Client control.

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6

Operation - API Shearer Safety Zone

6.3 Shearer Safety Zone The Shearer Safety Zone is the group of Shields around the Shearer, this group is inclusive of any shields defined by S_Ctd_Main, S_Ctd_Tail and the ACO safety zone.

Some API Client Auto Functions and equivalent From-To Group Functions in the PMC-R system cannot operate Shields within the Shearer Safety Zone. In this zone the operator does not have line of sight with the Shields being operated and a risk of collision with the Shearer is possible. The Shearer Safety Zone can only be established when communications are healthy between the PMC-R Shield system and the Shearer, for this reason different rules apply when the PMC-R Shields system detects both a valid and invalid shearer position, the effect on each group function is shown in Table 1 below.

Tab. 1: Functions with Shearer Safety Zone and Shearer Position Group Function

Initiated From

Valid Shearer Position

Invalid Shearer Position

Taper Batch Remote Group

Remote API

Not Allowed SSZ

Allowed NO SSZ

Taper Batch From-To Group

Face PMC-R

Not Allowed SSZ

Allowed NO SSZ

Batch Adjacent Group

Face PMC-R

Allowed SSZ

Allowed NO SSZ

Bankpush Remote Group

Remote API

Not Allowed SSZ

Allowed NO SSZ

Bankpush From-To Group

Face PMC-R

Not Allowed SSZ

Allowed NO SSZ

Bankpush Adjacent Group

Face PMC-R

**Not Allowed SSZ

Allowed NO SSZ

Bank Flipper Remote Group

Remote API

Not Allowed SSZ

Allowed NO SSZ

Bank Flipper From-To Group

Face PMC-R

Not Allowed SSZ

Allowed NO SSZ

Bank Flipper Adjacent Group

Face PMC-R

Allowed SSZ

Allowed NO SSZ

Single Shield Remote Control

Remote API

Not Allowed SSZ

Allowed NO SSZ

Adjacent Remote Control

Face PMC-R

Allowed SSZ

Allowed NO SSZ

**Narrabri software inhibits all Bankpush operations in the Shearer Safety Zone Key: Not Allowed SSZ = Not Allowed in Shearer Safety Zone

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Fig. 13: Shearer Safety Zone

Operation - API

6

Shearer Remote Safety Zone

Allowed SSZ = Allowed in Shearer Safety Zone Allowed NO SSZ = Allowed there is No Shearer Safety Zone

6.4 Shearer Remote Safety Zone The Shearer Remote Safety Zone is applied when the parameter Shr_Remote=ON, this safety zone replaces the usual Shearer Safety Zone and disables all Remote Control operations on the Tailgate side of the shearer. The Shearer Remote Safety Zone begins from the first Shield on the longwall and extends to Tailgate side of the Shearer defined by the S_Ctd Tail + ACO Safety Zone.

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Additional Shields on the Tailgate side of the Shearer can be included in the safety zone by setting of the Shr_Rem_offset parameter, starting from the center of the Shearer this parameter defines how many shields extending towards the Tailgate will be included in the safety zone.

When the Shearer Remote Safety Zone is in operation and the Shearer position is lost then no Remote Control functions from the Remote_SCU will be possible.

The usual Shearer Safety Zone will apply when Shr_Remote=OFF. Fig. 14: Shearer Remote Safety Zone

Tab. 2: Functions with Shearer Remote Safety Zone and Shearer Position Group Function

Initiated From

Valid Shearer Position

Invalid Shearer Position

Taper Batch Remote Group

Remote API

Not Allowed SRSZ

Not Allowed FW

Taper Batch From-To Group

Face PMC-R

Not Allowed SSZ

Allowed NO SRSZ/ SSZ

Batch Adjacent Group

Face PMC-R

Allowed SRSZ

Allowed NO SRSZ/ SSZ

Bankpush Remote Group

Remote API

Not Allowed SRSZ

Not Allowed FW

Bankpush From-To Group

Face PMC-R

Not Allowed SSZ

Allowed NO SRSZ/ SSZ

Bankpush Adjacent Group

Face PMC-R

**Not Allowed SSZ

Allowed NO SRSZ/ SSZ

Bank Flipper Remote Group

Remote API

Not Allowed SRSZ

Not Allowed NO FW

Bank Flipper From-To Group

Face PMC-R

Not Allowed SSZ

Allowed NO SRSZ/ SSZ

Bank Flipper Adjacent Group

Face PMC-R

Allowed SRSZ

Allowed NO SRSZ/ SSZ

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6

Operation - API Single Shield Commands

Group Function

Initiated From

Valid Shearer Position

Invalid Shearer Position

Single Shield Remote Control

Remote API

Not Allowed SRSZ

Not Allowed NO FW

Adjacent Remote Control

Face PMC-R

Allowed SRSZ

Allowed NO SRSZ/ SSZ

**Narrabri software inhibits all Bankpush operations in the Shearer Safety Zone Key: Not Allowed SRSZ = Not allowed in Shearer Remote Safety Zone Allowed SRSZ = Allowed in Shearer Remote Safety Zone Allowed NO SRSZ/SSZ = Allowed there is No Shearer Remote Safety Zone or Shearer Safety Zone Not Allowed FW = Not allowed Face Wide

6.5 Single Shield Commands Single Shield Commands control functions on a single shield only and first require the desired shield to be selected, the API client will handle this feature automatically whenever a single shield command is initiated. After the desired shield is selected each single shield command can be operated only once provided the PMC-R system allows the function to be performed. All API commands sent via the API client are viewable in the VShield API Server as each command received is logged in an event list, this can be used to verify the commands that have been sent and the response from the API Server.

The single shield select command is comprised as below, {{url}} represents the rest server address URL and {{ShieldNo}} represents the selected shield number. {{url}}/SingleFuncSelectShieldNum?ShieldNo={{ShieldNo}} After the selection command is sent the single shield function commands can be sent, this command is comprised as below, {{url}} represents the rest server URL, {{ManualFunction}} represent the desired manual function, {{TimeOut}} represents the time to operate the function and {{ShieldNo}} represents the selected shield number. {{url}}/shieldSingleFuncStart?singlefunc={{ManualFunction}}&timeout={{TimeOut}}&ShieldNo={{ShieldNo}} Once the single shield function is actioned on the PMC-R/PMC-R 2.0 system , if sensors can be used to determine targets for the functions then they are, this allows the A single shield function to be operated to a target value that is also used when the shield is operating automatically. An example is the advance function will have a target equal to the advance target setting. Targets for each Single Shield Remote Control function are specified in the ‘Limit’s column of Table 2.

Each function has a timeout and if the target is not reached within this time then the function output is de-energised. Timeout values for each Single Shield Command are those sent via the API command specifically the {{TimeOut}} parameter. If there is no sensor related to a function that allows a target to be determined then the function will operate to its related {{TimeOut}} parameter.

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Not Allowed SSZ = No allowed in the typical Shearer Safety Zone

Operation - API

6

Single Shield Commands

Specific items to note are: 1) The Lock On Push (ON/OFF) command does not use the {{TimeOut}} parameter of the API request but it must be populated with valid values for a successful request.

When a shield is placed in slave from the API Client a 5 second pre-warn is initiated in the shield before any valve activations are allowed. Any functions that are selected within the 5 second pre-warn period will wait until the pre-warn is complete before initiation.

If manual functions are disabled in a shield, then It will not be selectable for Single Shield Remote Control operations.

If a shield forms part of a PZone and the PPD Mode setting is greater than 1 then the shield will not be selectable for single shield remote control operations.

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Note: Applicable only with PPD (Personal Proximity Detection) Installed Only.

If a system pressure or return pressure trip exists, then shields will not be selectable for Single Shield Remote Control operations.

If a shield forms part of a Travel Zone, then the shield will not be selectable for Single Shield Remote control operations.

Some Single Shield Remote Control operations are prevented if either the shearer position is invalid or the shield that is in slave control forms part of the Shearer Safety Zone. The functions that are inhibited in these situations are specified in the ‘Inhibits’ column as ‘Shearer’ in Table 2.

The correctly selected shield will provide some sensor value information of the slave shield. However, delays are inevitable and fine control cannot be achieved by using these values as feedback.

Sending the unselect shield request will cancel the slave selection, this will be done automatically when shield numbers are changed using the command: {{url}}/SingleFuncUnSelectShieldNum?ShieldNo={{ShieldNo}}.

Any individual Single function can be initiated multiple times during a single Master time session on the Remote API. Functions, activations will not be stacked, so only once the previous function is complete only then will a new activation be started. i.e. sending API commands to activate an active function will be ignored by the PMC-R system.

Motion monitoring related inhibits are only applied when parameter MotionMonitor = 2.

Compensation Cylinder related inhibits are only applied when the local Comp Protect loc. Parameter is switched on in the shield.

Single Shield Commands are selectable while a Remote Group Function is operating but cannot be within the remote group function.

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6

Operation - API Single Shield Commands Tab. 3: Single Function Commands Function Lower

Limits (De-energised when)

Timeout Parameter

Inhibits

Both Left and Right Leg <= REM lower Press

{{TimeOut}} from the API command

Shearer Zone MinHeighStopH1 MinHeighStopH3 Sensors invalid or ignored

Advance

DA Ram <= ASQ St0 adv.stroke

{{TimeOut}} from the API command

Shearer Sensors invalid or ignored

Both L and R PSA P2

{{TimeOut}} from the API command

MM MaxCmpAng MM MinCmpAng

{{ManualFunction}} =ADVANCE Legs Set

Sensors invalid or ignored

{{ManualFunction}} =SET Base Lift

Timeout

{{TimeOut}} from the API command

MM MaxCmpAng MM MinCmpAng

Timeout

{{TimeOut}} from the API command

MinHeighStopH3 MM MaxCmpAng

{{ManualFunction}} =BASE_LIFT_EXT Tip Up

{{ManualFunction}} =TIP_SET

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{{ManualFunction}} =LOWER

Operation - API

6

Single Shield Commands

Function Tip Down

Limits (De-energised when)

Timeout Parameter

Inhibits

Timeout

{{TimeOut}} from the API command

Shearer MinHeighStopH1 MM MinCmpAng

DA Ram >= BP extens

{{TimeOut}} from the API command

Shearer Sensor invalid or ignored

both legs >= PSA hi set_P2

{{TimeOut}} from the API command

MM MaxCmpAng

Timeout

{{TimeOut}} from the API command

None

flipper ram stroke <= flp.ret.ram

{{TimeOut}} from the API command

Shearer Sensor invalid or ignored

{{ManualFunction}} =TIP_LOWER

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Ram Out

{{ManualFunction}} =PUSH Hi-Set

MM MinCmpAng

{{ManualFunction}} =HIGH_PRESS_SET Water Curtain

{{ManualFunction}} =WATER_CURTAIN Flipper Extend

Flipper Anti-Collision

{{AutolFunction}} =FLIPPER_EXT

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Operation - API Single Shield Commands

Function Flipper Retract

Limits (De-energised when)

Timeout Parameter

Inhibits

flipper ram stroke <= flp.ret.ram

{{TimeOut}} from the API command

Shearer Sensor invalid or ignored Flipper Anti-Collision

Side Seal OUT

Timeout

{{TimeOut}} from the API command

Timeout

{{TimeOut}} from the API command

Timeout

{{TimeOut}} from the API command

Timeout

{{TimeOut}} from the API command

{{ManualFunction}} =SIDE_SHIELD_EXT Side Seal IN

{{ManualFunction}} =SIDE_SHIELD_RET Side Seal 2 OUT

{{ManualFunction}} =SIDE_SHIELD2_EXT Side Seal 2 IN

{{ManualFunction}} =SIDE_SHIELD2_RET

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{{AutolFunction}} =FLIPPER_RET

Operation - API Single Shield Commands

Function Antitopple IN

Limits (De-energised when)

Timeout Parameter

Timeout

{{TimeOut}} from the API command

Timeout

{{TimeOut}} from the API command

6

Inhibits

{{ManualFunction}} =ANTITOPPLE_RET

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Side Water Spray

{{ManualFunction}} =WATER_SPRAY

The lock push is a special Single Shield Command it operates in a similar way however does not utilise the {{TimeOut}} API parameter and instead can be turned only ON or OFF via separate API commands, similar to the operation of the

key on the PMC-R/PMC-R 2.0 controllers.

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6

Operation - API Single Shield Commands Tab. 4: Lock On Push Command Function Lock On Push

Limits (De-energised when)

Timeout Parameter

Inhibits

DA Ram >= BP extens.

Not Applicable

None

OFF Command: {{ManualFunction}} =LOCK_ON_PUSH_O FF Fig. 15: Single Shield Remote Control Functions

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ON Command: {{ManualFunction}} =LOCK_ON_PUSH_O N

Operation - API Automatic Function Commands

6

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Fig. 16: Legs Lower Single Shield Remote Control Function

6.6 Automatic Function Commands Auto Function commands allow the operator to initiate automatic multi-shield sequences across groups of shields from the API Client. Each command that permits group functions have their own options on how the group is sequenced and controlled. For Automatic Functions some functions require first selecting start and end shields, others require no shield selection and the ASQ function requires selecting only a single shield. On top of the shield selection process some auto functions require additional fields to be selected, these are either start and end ram extensions or ON/OFF options.

Automatic Function Commands are comprised as below, {{url}} represents the rest server URL, {{AutolFunction}} represents the desired auto function, {{ShieldStart}} represents the start shield of a group, {{ShieldEnd}} represents the end shield of a group, {{ShieldExt0}} represents a ram extension target of the start shield and {{ShieldExt1}} represents a ram extension of the end shield. All API commands sent via the API client are viewable in the VShield API Server as each command received is logged in an event list, this can be used to verify the commands that have been sent and the response from the API Server. {{url}}/shieldAutoFuncStart?ShieldFrom={{ShieldStart}} &ShieldTo={{ShieldEnd}}&value1={{ShieldExt0}}&value2={{ShieldExt1}} &autoFunc={{AutoFunction}} Specific items to note are:

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6

Operation - API Automatic Function Commands

1. The ASQ function only uses the {{ShieldStart}} parameter in the API request however the {{ShieldEnd}} parameter must be populated with a valid value for a successful request.

2. The Bankpush MG (ON/OFF) and BankPush TG (ON/OFF) request do not use either the {{ShieldStart}} or {{ShieldEnd}} parameters of the API request but both must be populated with valid values for a successful request.

3. Only the Batch Ram Exts function requires the {{ShieldExt0}} and {{ShieldExt1}} parameters in the API request, these parameters maybe omitted from other requests.

Specific Requirements for Auto Function Commands to be successful are: Auto Function Commands cannot be initiated when there is a system pressure or return pressure trip.

On the API Client the correct group of shields must be selected prior to initiating each Auto Function Command.

Shield forming part of a Travel Zone prevents a Taper Batch, Batch and ASQ functions from operating when initiated from the Remote API. Conveyor Pullback group initiated from the Remote API is not possible under any circumstance.

PPD mode = 3 prevents Remote Taper Batch, Batch and ASQ functions from operating within the PPD Zone when initiated from the Remote API. Note: Applicable only with PPD (Personal Proximity Detection) Installed Only Warning!

PPD Mode 2 will allow Taper Batch, Batch or ASQ via The API Auto Command, the PPD system may detect persons with the Taper Batched group however the PMC-R system will not prevent shields advancing, persons may sustain serious injury should the shield they are standing on automatically advance.

Tab. 5: Auto Function Commands Function Bank Push Snake

Additional Params

Inhibitors

{{ShieldStart}} {{ShieldEnd}}

Shearer Zone

{{AutolFunction}}=BANKPUSH_SNAKE

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Bank push and Taper batch initiations are prevented if the shearer position is valid and the shield that is in being controlled forms part of the Shearer Safety Zone.

Operation - API Automatic Function Commands

Function Bank Push Taper

Additional Params

Inhibitors

{{ShieldStart}} {{ShieldEnd}}

Shearer Zone

{{ShieldStart}} {{ShieldEnd}}

Shearer Zone

{{ShieldStart}} {{ShieldEnd}}

Shearer Zone

6

{{AutolFunction}}=BANKPUSH_TAPER

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Bank Push All

{{AutolFunction}}=BANKPUSH_ALL Batch

Travel Zone (individual shields within group inhibited) Defective/Ignored DA Ram (individual shields within group inhibited PPD Mode = 3 {{AutolFunction}}=BATCH Batch to Ram Extents

{{ShieldStart}} {{ShieldEnd}} {{ShieldExt0}} {{ShieldExt1}}

Shearer Zone Travel Zone (individual shields within group inhibited) Defective/Ignored DA Ram (individual shields within group inhibited PPD Mode = 3

{{AutolFunction}} =BATCH_TO_RAM_EXTENS Bank Flipper Extend

{{ShieldStart}} {{ShieldEnd}}

Shearer Zone Parameter Auto Flippers = 1 or 2 Note: Bank Flipper operations allowed with SRB active or not if Auto Flippers=1

{{AutolFunction}}=FLIPPER_EXTEND

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6

Operation - API Automatic Function Commands

Function Bank Flipper Retract

Additional Params

Inhibitors

{{ShieldStart}} {{ShieldEnd}}

Shearer Zone Parameter Auto Flippers = 1 or 2 Note: Bank Flipper operations allowed with SRB active or not if Auto Flippers=1

{{AutolFunction}}=FLIPPER_RETRACT Water Curtain Group

{{ShieldStart}} {{ShieldEnd}}

Parameter AutoPosition Spray = 0 (Never)

AutoPosition Spray = 2 (Always)

{{AutolFunction}}=WATERCURTAIN Side Spray Group

{{ShieldStart}} {{ShieldEnd}}

Parameter Side Spray = 0 (Never) Side Spray = 1 (SRB Only)

{{ManualFunction}}=WATER_SPRAY

The ASQ (Autosequence) command is a special Auto Function Command that operates on a single shield only, this function will automatically advance the selected shield similar to pressing the single direction keys

or

plus the

as done on the PMC-R/PMC-R controller. This command restart key quires only a valid {{StartShield}} parameter, the {{EndShield}} parameter must be populated for a successful request however is not used to activate the function.

Tab. 6: ASQ Command Function ASQ

Additional Params

Inhibits

{{ShieldStart}} {{ShieldEnd}}

Shearer

Note: {{ShieldEnd}} required for successful request but only {{ShieldStart}} is used.

Travel Zone (Shield remains in ASQ wait until Travel Zone removed) Defective / Ignored DA Ram (individual shields within group inhibited) PPD Mode = 3

{{AutolFunction}}=ASQ

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AutoPosition Spray = 1 (SRB Only)

Operation - API Automatic Function Commands

Function ASQ Cancel

6

Additional Params

Inhibits

{{ShieldStart}} {{ShieldEnd}}

Cancels any active ASQ’s from {{ShieldStart}} to {{ShieldEnd}}

{{AutolFunction}}=ASQ_CANCEL

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The Bank Push MG and Bank Push TG are special Automatic Function Commands that operate exclusively on the MG Solid Group and TG Solid Group Shields only. These commands are the same as operating the BP MAIN and BP TAIL auxiliary functions on the PMC-R/PMC-R 2.0 controller.

Fig. 17: BP Mail/Tail Auxiliary Functions

As the shield selection is exclusive the {{ShieldStart}} and {{ShieldEnd}} parameters are not used however must be populated in the request, the functions are turned ON or OFF via separate API commands.

Tab. 7: BP MAIN/TAIL Auto Function Commands Function Bank Push MG

Additional Params

Inhibits

{{ShieldStart}} {{ShieldEnd}}

Shearer Zone

Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

ON Command: {{AutoFunction}}=BANKPUSH_MG_ON OFF Command: {{AutolFunction}}=BANKPUSH_MG_OFF Bank Push TG

{{ShieldStart}} {{ShieldEnd}}

Shearer Zone

Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

ON Command: {{AutoFunction}}=BANKPUSH_TG_ON OFF Command: {{AutolFunction}}=BANKPUSH_TG_OFF

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6

Operation - API SRB Commands

6.7 SRB Commands SRB Commands take the same form as the Automatic Function Commands but are specific to starting, restarting, suspending and cancelling the SRB (Shearer Running Batch) Function. These commands require the {{ShieldStart}} and {{ShieldEnd}} parameters in actioning the request however are not use to control the functions. All API commands sent via the API client are viewable in the VShield API Server as each command received is logged in an event list, this can be used to verify the commands that have been sent and the response from the API Server.

Tab. 8: BP MAIN/TAIL Auto Function Commands

New Start MG - TG

Additional Params

Inhibits

{{ShieldStart}} {{ShieldEnd}}

Invalid Shearer Position Incorrect Shearer Direction

Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

PMC-R Related Inhibits (See PMC-R Parameter Manual)

{{AutolFunction}}=SRB_NEWSTART_MG_TG New Start TG – SP

{{ShieldStart}} {{ShieldEnd}} Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

Invalid Shearer Position Incorrect Shearer Direction Uni-Di Operation PMC-R related Inhibits (See PMC-R Parameter Manual)

{{AutolFunction}}=SRB_NEWSTART_TG_SP New Start SP – TG

{{ShieldStart}} {{ShieldEnd}} Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

Invalid Shearer Position Incorrect Shearer Direction Uni-Di Operation PMC-R related Inhibits (See PMC-R Parameter Manual)

{{AutolFunction}}=SRB_NEWSTART_SP_TG New Start TG – MG

{{ShieldStart}} {{ShieldEnd}} Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

Invalid Shearer Position Incorrect Shearer Direction PMC-R related Inhibits (See PMC-R Parameter Manual)

{{AutolFunction}}=SRB_NEWSTART_TG_MG New Start MG - SP

{{ShieldStart}} {{ShieldEnd}} Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

Invalid Shearer Position Incorrect Shearer Direction Uni-Di Operation PMC-R related Inhibits (See PMC-R Parameter Manual)

{{AutolFunction}}=SRB_NEWSTART_MG_SP

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Function

Operation - API

6

SRB Commands

Function New Start SP - MG

Additional Params

Inhibits

{{ShieldStart}} {{ShieldEnd}}

Invalid Shearer Position Incorrect Shearer Direction Uni-Di Operation

Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

PMC-R related Inhibits (See PMC-R Parameter Manual)

{{AutolFunction}}=SRB_NEWSTART _SP_MG SRB Cancel

{{ShieldStart}} {{ShieldEnd}}

None

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Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

{{AutolFunction}}=SRB_CANCEL Restart

{{ShieldStart}} {{ShieldEnd}}

SRB = Off

Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

Note: SRB can only be restarted in SRB = Suspend

{{ShieldStart}} {{ShieldEnd}}

None

{{AutolFunction}} =SRB_RESTART Suspend

Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

{{AutolFunction}}=SRB_SUSPEND Important!

Sending the SRB Suspend command is the same as pressing the Stop Key on the PMC-R so all active functions will stop when command is received by the PMC-R system.

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Operation - API Dump Valve Commands

6.8 Dump Valve Commands The Dump Valve Commands take the same form as the Automatic Function Commands but are specific to enabling the Dump Valve to be Controlled From the API. All API commands sent via the API client are viewable in the VShield API Server as each command received is logged in an event list, this can be used to verify the commands that have been sent and the response from the API Server.

The API Dump valve commands can be ignored in the PMC-R/PMC-R 2.0 system by setting the L4 Password parameter REM VISU Dump ign. = 1.

Caution!

Dump Valve Energisation

Function Dump Valve

Additional Params

Inhibits

{{ShieldStart}} {{ShieldEnd}}

PMC-R parameter REM VISU Dump Ign = 1

Note: {{ShieldStart}} and {{Shield}} required for successful request but both are not used.

ON Command:{{AutoFunction}} =DUMP_VALVE_ON OFF Command:{{AutolFunction}} =CANCEL_ALL_DUMP_VALVE

6.9 Anti-collision Override Command The anti-collision override command is a special auto function command that enable an active Shearer (Front) anticollision the command will be assessed by the PMC-R/PMC-R 2.0 system and applied as per the required conditions.

There are some additional conditions for the Rear AFC anti-collision however the anti-collision override API command is not used for overriding the Rear AFC anti-collision.

Automatic Function Commands are comprised as below, {{url}} represents the rest server URL, {{AutoFunction}} represents the desired auto function, {{ShieldStart}} represents the start shield of a group, {{ShieldEnd}} represents the end shield of a group. {{url}}/shieldAutoFuncStart?ShieldFrom={{ShieldStart}} &ShieldTo={{ShieldEnd}} Specific Requirement for Anti-collision override API Command: The API command can be sent to any single or group of shields as required at anytime.

The PMC-R 2.0 system will decide whether to apply the anti-collision override command as it deems fit.

Specific Conditions for Shearer Anti-Collision (PMC-R Logic):

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When ignoring the Dump Valve API Commands via the PMC-R System, the dump valve may immediately become energized, The API Dump Command is not to be used as isolation of the dump valve, ensure correct dump valve isolation procedures are used.

Operation - API

6

Stacked Commands

When Shearer anti-collision has been activated it may be overridden via the VShieldSingle API command pending the shearer is deemed to be stationary. Before overriding the collision, some VShieldSingle API functions will be allowed with an active anti-collision in order to clear it, if it cannot be cleared then the override can be used.

With an active Shearer anti-collision, the anti-collision is displayed on VShield or VShieldSingle (with relevant shield selected) If a flipper is extended, then it can be retracted, this operation will be allowed from the VShieldSingle API with an active anti-collision warning provided the shearer is stationary.

If the Shield is set, then the Shearer drum can be lowered below the minimum limit.

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If the maximum lowering time is operated, then the shield can be reset to the roof, the legs raise function will be allowed from the VShieldSingle API with an active anti-collision.

If the anti-collision cannot be cleared by the above means, then it can be overridden from the VShieldSingle API enabling all operations to continue.

Warning!

Ignoring ram stroke sensors will defeat anti- collision protection related to the particular ram. For example, a flipper ram stroke sensor that has an ignored will operate to timers during its automatic extension/retraction. It is possible that the flipper can be fully extended but it will not generate an anti-collision with the shearer as its sensor is ignored.

Tab. 9: Anti-collision Override Command Function Anti-collision Override

Additional Params

Inhibits

{{ShieldStart}} {{ShieldEnd}}

PMC-R Allows or disallows given the requirements above

{{AutolFunction}}=ANTICOLL_OVERRIDE

6.10 Stacked Commands Multiple Automatic/Group Functions should be able to be started from the API in succession or stacked, the PMC-R/PMC-R 2.0 system will perform appropriate control action when a shield is requested to perform multiple automatic/group functions at once.

Single Shield API commands should be able to be started while Automatic/ Group Functions are operating, the PMC-R/PMC-R 2.0 system will take appropriate control action when a shield is requested to perform both single shield and automatic/group functions at once.

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Operation - API User Log In/Logout

6.11 User Log In/Logout Login To login you must click the login button located in the top right hand corner.

Fig. 18: Login Button

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After clicking the login button a login screen will open where the user may enter their username and password.

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Operation - API User Log In/Logout

6

If the login credential are not correct the ‘401 Unauthorised:Unauthorised user” message will be displayed and the user will not be granted access.

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Fig. 19: Login Screen

Fig. 20: Login Screen user unauthorised

Logout To logout you must click the three vertical dots in the top right hand corner and select the logout option.

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Operation - API User Log In/Logout

A confirmation window will appear and the user must confirm they wish to logout.

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Fig. 21: Logout Button

Fig. 22: Logout Confirmation

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Operation - API User Log In/Logout

6

6.11.1 Session Expiry If the user does not interact with the program for 15 minutes a popup message appears warning the operator they are about to be logged out, to continue to stay logged in the user will need to press the ‘Extend’ button to reset the inactivity timer.

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If the user does not extend the session and the inactivity timer expires then they will be automatically logged out of the API Client.

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6

Operation - API Controls Panel

6.12 Controls Panel The Controls Panel is the first panel seen when logging in and allows access to collections of API commands, but does not contain direct commands itself.

Shield selection in this panel is the same as the manual selection option when not logged in to the API Client and auto selection is disabled once logged in to the API Client.

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Fig. 23: Controls Panel

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Operation - API Controls/Single Panel

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6.13 Controls/Single Panel The Controls/Single Panel contains a collection of API commands for single shield manual control. There two types of commands that can be displayed depending on the function that is selected, this will either be a command that requires an operating time to be entered or an On/Off selection. When a function is selected it is highlighted light blue otherwise if unselected will be grey.

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Fig. 24: Controls Single Panel

6.13.1 Shield Selection Shield selection in this panel is the same as the manual selection option when not logged in to the API Client and auto selection is disabled once logged in to the API Client. Before sending any Controls/Single command first the desired

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6

Operation - API Controls/Single Panel

shield must be selected using either the Shield Selection Text or Shield Face Wide/Focused Selection Bar, this determines the shield number that will receive and action the API command.

Fig. 25: Controls/Single Shield Selection

6.13.2 Operating Time Controls

The operating time is maintained independently for each function, and the value is maintained as the last entered value when the function was selected, last entered values are maintained through program restart so restarting the program should restore the last entered value.

Fig. 26: Operating Time Entry

Fig. 27: Operating Time Out of range

6.13.3 On/Off Controls For single shield commands using the On/Off selection if the function is not operating already then only the On selection will be relevant and sending with On selected will request the function to activate. Once the function is activated then only the Off command is relevant and sending the Off command will request the function to de-activate.

Fig. 28: On/Off Selection

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For single shield commands utilising the Operating Time entry this defines the time in which the function will operate for in milliseconds. The minimum value that can be entered is 50ms and the maximum is 5000ms, only numbers in this range are accepted, if out of range the numbers will indicate red and the last valid value will be applied.

Operation - API Controls/Single Panel

6

6.13.4 Send Command The ‘Send’ button is used to issue commands to the API Server once the correct selections have been made.

Fig. 29: Send Button

6.13.5 Command Response The Server will return the result of the command whether successful or unsuccessful along with a description of why the command failed.

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Fig. 30: Command Success

Fig. 31: Command Failure

6.13.6 Changing Shield Selection Changing the shield selection when in the Control/Single Panel will issue an unselect command to the previous selected shield, issuing of the unselect command will immediately cause the slave mode on the previous selected shield to be cancelled and the shield will return to Idle mode, in doing this any active functions on the previously selected shield will be cancelled.

Fig. 32: Un-selection Command Response

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6

Operation - API Controls/Auto Panel

6.14 Controls/Auto Panel The Controls/Auto Panel provides a collection of commands that can operate shield/s in an automatic sequence. For the automatic functions some functions require first selecting start and end shields, others require no shield selection and the ASQ function requires selecting only a single shield. On top of the shield selection process some auto functions require additional fields to be selected, these are either start and end ram target extensions or ON/OFF options.

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Fig. 33: Controls/Auto Panel

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Operation - API Controls/Auto Panel

6

6.14.1 Start/End Shield Selection For functions requiring a group of shields to operate then the shield selection allows for this adding an additional text entry box, the left hand text entry is for the Start Shield of the group and the right hand the End Shield of the group. When both text boxes are populated with different numbers the shields between them will highlight blue in the Face Wide Shield Selection bar. There is no Focused Shield Selection bar when the Start/End Shield selection is applied.

Fig. 34: From-To Shield Selection

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To select the Start/End Shield the user can simply type the desired start and end shield numbers in the text boxes, the numbers from Start to End can be high to low or low to high as in the PMC-R/PMC-R 2.0 system as generally for group functions they can be applied in either direction with different outcomes.

Fig. 35: Low to High Shield selection

Fig. 36: High to Low Shield Selection

Face Wide Shield Selection bar can be used to set both the start and end entry parameters to the same number, after which the user can then edit either the start or end text entry box to complete the group selection.

Fig. 37: Graphical selection

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6

Operation - API Controls/Auto Panel

6.14.2 ASQ Shield Selection Shield selection for when the ASQ function is selected reverts to manual selection option when not logged in to the API Client and auto selection is disabled once logged in to the API Client. Before sending the ASQ command first the desired shield must be selected using either the Shield Selection Text or Shield Face Wide/Focused Selection Bar, this determines the shield number that will receive and action the API command.

Fig. 38: ASQ Shield Selection

For automatic commands using the On/Off selection there is no need to select any shields first, the selection can be arbitrary so the user may select the shield they want to visualise with no affect when sending the command.

If the On/Off function is not operating already then only the On selection will be relevant and sending with On selected will request the function to activate.

Once the function is activated then only the Off command is relevant and sending the Off command will request the function to de-activate.

Fig. 39: On/Off Selection

6.14.4 Start/End Control For functions that require only Start / End shields selected there will be no other options available for this control. With the correct Start / End shield’s selected the user can send the command.

6.14.5 Start/End with Target Control For functions that require start/end shields as well as start/end targets, an additional target selection box will be available with the left hand start shield box entry corresponding to the top target entry box, therefore the end shield entry box corresponds to the bottom target entry box, the corresponding shield number is displayed along side the target entry box for reference.

The targets are entered as a percentage 0-100% and any other values outside of this range will not be accepted, if they are entered the numbers will indicate red, will not be saved and the previous valid value will be restored.

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6.14.3 On/Off Control

Operation - API Controls/Auto Panel

6

Once the correct start/end shields and start/end targets are selected the user can send the command.

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Fig. 40: Start/End with Target Correlation

6.14.6 ASQ Control The ASQ control is a special automatic function that operates on a single shield only therefore the ASQ Shield selection requires only a single to be selected and there will be no other options available for this control.

6.14.7 Send Command The ‘Send’ button is used to issue commands to the API Server once the correct selections have been made.

Fig. 41: Send Button

6.14.8 Command Response The Server will return the result of the command whether successful or unsuccessful along with a description of why the command failed.

Fig. 42: Command Success

Fig. 43: Command Failure

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6

Operation - API Controls/SRB Panel

6.15 Controls/SRB Panel The Controls/SRB Panel contains a collection of API commands specifically for starting, restarting, suspending and cancelling the SRB (Shearer Running Batch) Function.

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Fig. 44: Control/SRB Panel

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Operation - API Controls/SRB Panel

6

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Fig. 45: SRB Controls

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6

Operation - API Controls/Dump Panel

6.15.1 Shield Selection Shield selection in this panel is the same as the manual selection option when not logged in to the API Client and auto selection is disabled once logged in to the API Client. The shield selection when in this panel performs no function other than selecting which shield to view as the Controls/SRB commands do not require selection of specific shields.

Fig. 46: Controls/SRB Shield Selection

For the SRB commands the shield selection can be arbitrary so the user may select the shield they want to visualise with no affect when sending the command.

After selecting the desired SRB command the user may immediately action the API command by pressing the Send button.

6.15.3 Send Command The ‘Send’ button is used to issue commands to the API Server once the correct selections have been made.

Fig. 47: Send Button

6.15.4 Command Response The Server will return the result of the command whether successful or unsuccessful along with a description of why the command failed.

Fig. 48: Command Success

Fig. 49: Command Failure

6.16 Controls/Dump Panel The Controls/Dump panel contains a collection of commands specific to allow the control of the hydraulic fluid supply to the Shields via energizing or de-energizing the Dump Valve. This functionality is intended as an additional control should the remote operator wish to control hydraulic fluid supply to the Shields.

The Dump Valve API commands should not be used for isolating hydraulic fluid supply as the commands can be overridden via the L4 PMC-R parameter REM VISU Dump ign.=1.

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6.15.2 SRB Controls

Operation - API Controls/Dump Panel

6

Danger!

Do not use the API dump valve commands for isolation of the hydraulic fluid supply, they can be overridden via PMC-R parameters causing the dump valve to become energized.

Possible consequences are very serious or even death.

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Fig. 50: Controls/Dump Panel

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Operation - API Controls/Dump Panel

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Fig. 51: Dump Valve Control

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Operation - API Controls/Dump Panel

6

6.16.1 Shield Selection Shield selection in this panel is the same as the manual selection option when not logged in to the API Client and auto selection is disabled once logged in to the API Client. The shield selection when in this panel performs no function other than selecting which shield to view as the Controls/Dump commands do not require selection of specific shields.

Fig. 52: Controls/SRB Shield Selection

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6.16.2 Dump Valve Control The Dump Valve Command requires selecting either the On or Off selection to be made before actioning the request via the send button. If the Dump Valve is energized then the Dump Valve Off command can be used to de-energize the dump valve.

Danger!

Do not use the API Dump Valve Off commands for isolation of the hydrualic fluid supply, The reverse command can be easily sent or it can be overridden via PMC-R parameters causing the dump valve to become energized.

Possible consequences are very serious or even death.

If the Dump Valve was de-energized via the Dump Valve Off command then the Dump Valve On command can be used to re-enable the dump valve to become energized. The API Dump Valve commands operate independent to other systems controlling the Dump Valve so sending the On command will re-enable the Dump Valve to become energized via the API however, other systems such as the PMC-R/PMC-R 2.0 system may still prevent the Dump Valve from energizing.

Important!

The Dump Valve On command will only counteract the Dump Valve Off command, it will not override other systems preventing the dump valve from energizing.

Fig. 53: On/Off Selection

6.16.3 Send Command The ‘Send’ button is used to issue commands to the API Server once the correct selections have been made.

Fig. 54: Send Button

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Operation - API Stop Button/Stop Key

6.16.4 Command Response The Server will return the result of the command whether successful or unsuccessful along with a description of why the command failed.

Fig. 55: Command Success

Fig. 56: Command Failure

The STOP button is persistent at the top of all API control panels making it available to the user at all times.

Fig. 57: Stop Button

The STOP button suspends SRB and cancels all active automatic and single shield functions when operated, therefore to prevent stopping mining operations in a single unintended click the user is asked to confirm his decision to send the API stop command.

In fact the API stop command is the same command as SRB Command “SRB_SUSPEND” and therefore the request will take the same form if viewed in VShield API server event list.

6.18 User Administration Access to program installation and configuration files should be controlled via the system administrator to prevent unauthorised access.

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6.17 Stop Button/Stop Key

Maintenance

7

7 Maintenance As mine sites undergo changes to equipment the shield face layout and shield sensor configuration can be altered. Should this be the case the VDataSrv and VShieldSingle application may need to have the configuration modified or in some cases require an update to VShieldSingle application and/or pre-requisite programs.

Caution!

Change to equipment layout and configuration

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Changes to the face layout and shield sensor configuration may compromise the information shown in VShieldSingle. Please consult Caterpillar© when changes to equipment are required to ensure the ongoing reliability of the VShieldSingle program.

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8

Reference Information

8 Reference Information Applicable PMC-R Operator & Maintenance Manual Applicable PMC-R Parameter Manual Applicable PMC-R Remote Control Operator & Maintenance Manual Applicable PMC-R Surface Remote Control (SRC) Operator & Maintenance Manual VShield Operation & Maintenance Manual VShield REST API Manual

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VUserManagement Operation & Maintenance Manual

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Shield Types

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9 Shield Types The following diagrams detail the required shield type or types to cover the relevant shield types that could potentially move to Remote Control operation and require the functionality of VShieldSingle.

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Fig. 58: Two Leg Shield with Inclinometer and Flipper

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10 Shield Config 10 Shield Config The current functionality within the VShield Single Config XML would allow the defined shield types to be defined in regard to the following: SystemMaxPressure 600 Shield 1-196: DACylinderLength 1080 Flipper = 547 Forepole = N/A

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Inclinometer = True

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Appendix

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11 Appendix The VShieldSingle installation folder contains the file vshield_single_app_config.xml. This XML must be configured to reflect the PMC-R system at the mine site.

1. Configure the VDatasrv IP Address.

Example with VDataSrv running on local the local host, if VDataSrv is not the local host then use the IP address of PC running VDataSrv <config-bytearray name="VDataSrvIpAddress" val="127.0.0.1"/> 2. The Remote_SCU setting is commented out as there is no Remote_SCU in system. <!--<config-bytearray name="ShieldRemote" val="No481"/>--> 3. Configure the TCC (Top Coal Caving).

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<config-bool name="AutoTCCInfoEnable" val="false"/> 4. Configure the RCP (Rear Conveyor Pull). <config-bool name="AutoRCPEnable" val="false"/> 5. Configure the PPD (Personal Proximity Protection). <config-bool name="PPDEnable" val="false"/> 6. Configure the Inclinometer system <config-bool name="InclinometerEnable" val="true"/> 7. Configure Shield types in the network to match the mine configuration.

The following Shield types and options are available: Shield Type = STD2LegV2 Sensor Config = ShieldConfig_STD2LegV2_1 Flipper = No Forepole= No <config-group name="No001"> <config-bytearray name="Type" val="STD2LegV2"/> <config-bytearray name="Config" val="ShieldConfig_STD2LegV2_1"/> <config-bool name="FlipperEnable" val="true"/> <config-bool name="ForepoleEnable" val="false"/> </config-group> <config-group name="No002"> <config-bytearray name="Type" val="STD2LegV2"/> <config-bytearray name="Config" val="ShieldConfig_STD2LegV2_1"/> <config-bool name="FlipperEnable" val="true"/> <config-bool name="ForepoleEnable" val="false"/> </config-group> .. .. .. <config-group name="No195"> <config-bytearray name="Type" val="STD2LegV2"/>

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11 Appendix <config-bytearray name="Config" val="ShieldConfig_STD2LegV2_1"/> <config-bool name="FlipperEnable" val="true"/> <config-bool name="ForepoleEnable" val="false"/> </config-group> <config-group name="No196"> <config-bytearray name="Type" val="STD2LegV2"/> <config-bytearray name="Config" val="ShieldConfig_STD2LegV2_1"/> <config-bool name="FlipperEnable" val="true"/> <config-bool name="ForepoleEnable" val="false"/> </config-group> 8. Set the range of the pressure sensors, typically 600 Bar. <config-group name="ShieldConfig"> </config-group> 9. Each Shield type has a cylinder length configuration and needs to be configured for the specific shield types, Shield types and cylinder length configuration is as follows. <config-group name="ShieldConfig_STD2LegV2_1"> <config name="FlipperCylinderLength" val="547"/> <config name="DACylinderLength" val="1080"/> <config name="ForepoleCylinderLength" val="1080"/> </config-group> The VShieldSingle installation folder contains the shield_control_config.json this JSON file must be configured to reflect the mines network setup and the API commands available for the installed PMC-R application.

1. To set change the address of the API Server the fields below can be edited in the shield_control_config.json file, set the correct IP address and port of the REST API Server here: restServerIp": "127.0.0.1:8089" 2. Please consult a Caterpillar for customization of the API Commands available in the VShieldSingle application.

Caution!

Incorrect Configuration File Incorrectly editing the API Commands in the shield_control_config.json file may cause the VSheidSingle program to function incorrectly. Verification of the program operation is required after editing of the configuration file.

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<config name="SystemMaxPressure" val="600"/> <!--600 Bar-->