Abstract: A longwall mining system including a longwall shearer having cutting drums. The cutting picks on the cutting drum are monitored for wear using imaging devices mounted to the longwall mining system. Methods for monitoring wear includes a controller receiving image data from an imaging device directed at a cutting drum of a shearer. The controller analyzes the image data to determine a wear level of a cutting pick on the cutting drum. The controller then determines the wear level exceeds a wear threshold and, in response, generates an alert indicating that the cutting pick is worn in response to determining that the wear level exceeds the wear threshold.

Abstract: Methods and systems of monitoring and controlling a longwall mining system. One system includes a shearer including a cutter drum and a sensor mounted to the shearer. The system also includes an electronic controller including a processor and a memory, the electronic controller communicatively coupled to the sensor. The electronic controller is configured to receive vibration data from the sensor and determine a current vibration level experienced by the cutter drum. The electronic controller is also configured to compare the current vibration level to a target vibration threshold associated with a target material seam. The electronic controller is also configured to provide a visual output to an operator of the longwall mining system when the current vibration level exceeds the target vibration threshold, where the current vibration level exceeds the target vibration threshold when the cutter drum of the shearer cuts outside of the target material seam.

Abstract: Methods and systems of monitoring and controlling a longwall mining system. One system includes a shearer including a cutter drum and a sensor mounted to the shearer. The system also includes an electronic controller including a processor and a memory, the electronic controller communicatively coupled to the sensor. The electronic controller is configured to receive vibration data from the sensor and determine a current vibration level associated with the shearer based on the vibration data. The electronic controller is also configured to compare the current vibration level to a vibration threshold. The electronic controller is also configured to, in response to the current vibration level exceeding the vibration threshold, adjust a cutting parameter for the cutter drum of the shearer. The electronic controller is also configured to control the cutter drum with the adjusted cutting parameter.

Abstract: Methods and systems of monitoring and controlling a longwall mining system. One system includes a shearer including a cutter drum and a sensor mounted to the shearer. The system also includes an electronic controller including a processor and a memory. The electronic controller is configured to receive an impact event indication associated with an impact event of the cutter drum, the impact event indication based on vibration data collected by the sensor. The electronic controller is also configured to retrieve additional data associated with the impact event indication and link the additional data with the vibration data of the impact event indication. The electronic controller is also configured to create and store an impact event record including the vibration data and the additional data. The electronic controller is configured to, in response to receiving a maintenance request, export the impact event record for display.

Abstract: Methods and systems of monitoring and controlling a longwall mining system. One system includes a shearer including a cutter drum and a sensor mounted to the shearer. The system also includes an electronic controller including a processor and a memory, the electronic controller communicatively coupled to the sensor. The electronic controller is configured to receive vibration data from the sensor and determine a current vibration level experienced by a cutter drum of the shearer based on the vibration data. The electronic controller is also configured to compare the current vibration level to a vibration threshold. The electronic controller is also configured to detect an impact event associated with the cutter drum of the shearer based on the comparison and generate an impact event indication associated with the impact event.

Abstract: A longwall mining system including a longwall shearer having cutting drums. The cutting picks on the cutting drum are monitored for wear using imaging devices mounted to the longwall mining system. Methods for monitoring wear includes a controller receiving image data from an imaging device directed at a cutting drum of a shearer. The controller analyzes the image data to determine a wear level of a cutting pick on the cutting drum. The controller then determines the wear level exceeds a wear threshold and, in response, generates an alert indicating that the cutting pick is worn in response to determining that the wear level exceeds the wear threshold.

Abstract: Methods and systems of monitoring and controlling a longwall mining system. One system includes a shearer including a cutter drum and a sensor mounted to the shearer. The system also includes an electronic controller including a processor and a memory, the electronic controller communicatively coupled to the sensor. The electronic controller is configured to receive vibration data from the sensor and determine a current vibration level experienced by the cutter drum. The electronic controller is also configured to compare the current vibration level to a target vibration threshold associated with a target material seam. The electronic controller is also configured to provide a visual output to an operator of the longwall mining system when the current vibration level exceeds the target vibration threshold, where the current vibration level exceeds the target vibration threshold when the cutter drum of the shearer cuts outside of the target material seam.

Abstract: Methods and systems of monitoring and controlling a longwall mining system. One system includes a shearer including a cutter drum and a sensor mounted to the shearer. The system also includes an electronic controller including a processor and a memory, the electronic controller communicatively coupled to the sensor. The electronic controller is configured to receive vibration data from the sensor and determine a current vibration level associated with the shearer based on the vibration data. The electronic controller is also configured to compare the current vibration level to a vibration threshold. The electronic controller is also configured to, in response to the current vibration level exceeding the vibration threshold, adjust a cutting parameter for the cutter drum of the shearer. The electronic controller is also configured to control the cutter drum with the adjusted cutting parameter.

Abstract: Methods and systems of monitoring and controlling a longwall mining system. One system includes a shearer including a cutter drum and a sensor mounted to the shearer. The system also includes an electronic controller including a processor and a memory. The electronic controller is configured to receive an impact event indication associated with an impact event of the cutter drum, the impact event indication based on vibration data collected by the sensor. The electronic controller is also configured to retrieve additional data associated with the impact event indication and link the additional data with the vibration data of the impact event indication. The electronic controller is also configured to create and store an impact event record including the vibration data and the additional data. The electronic controller is configured to, in response to receiving a maintenance request, export the impact event record for display.

Abstract: Methods and systems of monitoring and controlling a longwall mining system. One system includes a shearer including a cutter drum and a sensor mounted to the shearer. The system also includes an electronic controller including a processor and a memory, the electronic controller communicatively coupled to the sensor. The electronic controller is configured to receive vibration data from the sensor and determine a current vibration level experienced by a cutter drum of the shearer based on the vibration data. The electronic controller is also configured to compare the current vibration level to a vibration threshold. The electronic controller is also configured to detect an impact event associated with the cutter drum of the shearer based on the comparison and generate an impact event indication associated with the impact event.

Abstract: An industrial machine including a sensor and a controller. The sensor is configured to sense a characteristic of a fluid of the industrial machine. Wherein the characteristic is indicative of a contaminant level. The controller has an electronic processor and a memory. The controller is configured to receive a signal from the sensor indicative of the contaminant level, compare the contaminant level to a threshold, and upon the contaminant level crossing the threshold perform at least one selected from a group consisting of output an alert, and commence a shutdown procedure of the industrial machine.

Abstract: An industrial machine including a sensor and a controller. The sensor is configured to sense a characteristic of a fluid of the industrial machine. Wherein the characteristic is indicative of a contaminant level. The controller has an electronic processor and a memory. The controller is configured to receive a signal from the sensor indicative of the contaminant level, compare the contaminant level to a threshold, and upon the contaminant level crossing the threshold perform at least one selected from a group consisting of output an alert, and commence a shutdown procedure of the industrial machine.

Abstract: A drive assembly for a mining machine. The drive assembly includes one-and-only-one sprocket and a housing coupled to the mining machine. The housing includes a shoe and at least partially receives the sprocket. The drive assembly also includes a motor and a drive shaft that couples the sprocket and the motor. The drive shaft rotates the sprocket and defines a longitudinal axis. The housing rotates relative to the mining machine about the longitudinal axis and in a face-to-gob direction.

Abstract: A longwall shearer is positioned adjacent a face conveyor for transporting material that is cut from a mining face. The longwall shearer includes a chassis, an arm pivotably coupled to the chassis, a cutting drum for engaging the mining face, and a lump breaker for engaging material on the face conveyor. The chassis includes a first end and a second end, and the chassis is movable in at least a first direction that is generally parallel to the mining face. The cutting drum is rotatably supported on the arm. The lump breaker is pivotably coupled to the chassis about an axis, and the lump breaker includes at least one tooth for breaking apart the cut material.

Abstract: A longwall shearer or other machine with a gear case for transmitting rotational power from a drive to a driven member. The gear case comprises a drive, a driven member, at least one axle including at least one aperture formed therein to circulate cooling fluid through the axle, and a gear mounted to rotate on the axle and positioned to transmit power from the drive to the driven member.

Abstract: A chain link assembly, a cable chain assembly and a mining system. The cable handler individual links may include an enclosed section for the fiber optic cable separate from other services for the machine. A flexible material or other structure may assemble the fiber optic cable in the cable handler in a manner in which it “snakes” about the centerline to provide ample slack in the fiber optic cable to, for example, prevent over tension.

Abstract: A drive assembly for a mining machine. The drive assembly includes one-and-only-one sprocket and a housing coupled to the mining machine. The housing includes a shoe and at least partially receives the sprocket. The drive assembly also includes a motor and a drive shaft that couples the sprocket and the motor. The drive shaft rotates the sprocket and defines a longitudinal axis. The housing rotates relative to the mining machine about the longitudinal axis and in a face-to-gob direction.

Abstract: A mining machine for mining along a mining face includes a longwall shearer, a product removal system for removing product cut by the longwall shearer, and a drive system for moving the longwall shearer along a rack extending along the mining face. The drive system including a housing coupled to the longwall shearer, a motor, and a sprocket at least partially positioned within the housing and drivingly connected to the motor. The sprocket is engaged with the rack and moves the longwall shearer along the rack. A shoe maintains the sprocket in engagement with the rack. The housing is configured to rotate relative to the longwall shearer such that the drive system adjusts for vertical height variations and horizontal variations of the rack.

Abstract: A longwall shearer is positioned adjacent a face conveyor for transporting material that is cut from a mining face. The longwall shearer includes a chassis, an arm pivotably coupled to the chassis, a cutting drum for engaging the mining face, and a lump breaker for engaging material on the face conveyor. The chassis includes a first end and a second end, and the chassis is movable in at least a first direction that is generally parallel to the mining face. The cutting drum is rotatably supported on the arm. The lump breaker is pivotably coupled to the chassis about an axis, and the lump breaker includes at least one tooth for breaking apart the cut material.

Abstract: A control system monitors the angle of each ranging arm, with respect to the mainframe of the machine. While the machine is in a defined zone along the face, if the angle of the arm is detected to be lower than a parameter defined set-point called the undercut limit, the control system does not allow the arm to be lowered further. When entering the run of face from either gate end, if either of the ranging arms are below the set point, the horizontal movement of the shearer is stopped, and an alarm message is generated, and a warning light begins to flash, alerting the operator that he must raise the arm before horizontal movement of the shearer can be enabled.