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Mining Controls

Caterpillar is the global market leader and supplier of complete longwall systems. All over the world, our equipment and systems are meeting the demands of underground mining under the most stringent conditions. Adapted to the mining challenges faced by our customers today, Cat customized systems range from hydraulic roof supports, automated plow systems, shearers, face conveyors and drive systems to automation and roof support carriers.Caterpillar delivers your system of choice, from low to high seam heights, for the longest longwalls and highest production demands.

PMC-D/PMC-D20 Drive Control Unit

The intrinsically safe Cat® PMC-D control is used on shearer or plow faces to provide high level AFC (armed face conveyor) and plow automation. Each Drive unit needs to be equipped with one PMC-D control unit and equivalent I/O to operate the CST drives or UEL gearbox functions. In such a system a Cat PMC-V provides the Human Machine Interface (HMI) to interfere with the PMC-D controls to operate manual mode, visualize and change parameters and show actual process values. Within a PMC-D system minimum one and typically up to 3 PMC-Vs are in equal operation. The PMC-D system can control extremely sensitive the speed and torque of highly powered AFC CST drive. Using Profibus network all PMC-Ds and PMC-Vs in a system could exchange process data over long distances with high frequency.

  • Specification Summary

  • Operating System µITRON RTOS
  • Processor 32Bit RISC Microcontroller TX1940CYAF, 32MHz, internal RAM 10Kbytes, ROM 256Kbytes
  • RAM Memory 4Mbytes CMOS Static RAM, 4Mbytes Flash
  • Socket 1 – Pin 1 Optocoupler Anode
  • Product Brochure

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Product Details

Components

Operating System µITRON RTOS
Processor 32Bit RISC Microcontroller TX1940CYAF, 32MHz, internal RAM 10Kbytes, ROM 256Kbytes
RAM Memory 4Mbytes CMOS Static RAM, 4Mbytes Flash

Electrical Sockets

Socket 1 – Pin 1 Optocoupler Anode
Socket 1 – Pin 2 Relay Contact NO: a
Socket 1 – Pin 3 Relay Contact NO: b
Socket 1 – Pin 4 Optocoupler Cathode
Socket 10 – Pin 1 +12 V (output)
Socket 10 – Pin 2 Multi Mode Input 3
Socket 10 – Pin 3 +8.2 V (output)
Socket 10 – Pin 4 GND
Socket 11 – Pin 1 +12 V (output)
Socket 11 – Pin 2 Multi Mode Input 6
Socket 11 – Pin 3 +8.2 V (output)
Socket 11 – Pin 4 GND
Socket 12 – Pin 2 TP a
Socket 12 – Pin 3 TP b
Socket 13 – Pin 2 CM-Sensor +
Socket 13 – Pin 3 CM-Sensor -
Socket 13 – Pin 4 CM-GND
Socket 14 – Pin 2 CM-Sensor +
Socket 14 – Pin 3 CM-Sensor -
Socket 14 – Pin 4 CM-GND
Socket 15 – Pin 2 CM-Sensor +
Socket 15 – Pin 3 CM-Sensor -
Socket 15 – Pin 4 CM-GND
Socket 16 – Pin 2 CM-Sensor +
Socket 16 – Pin 3 CM-Sensor -
Socket 16 – Pin 4 CM-GND
Socket 17 – Pin 2 CM-Sensor +
Socket 17 – Pin 3 CM-Sensor -
Socket 17 – Pin 4 CM-GND
Socket 18 – Pin 2 CM-Sensor +
Socket 18 – Pin 3 CM-Sensor -
Socket 18 – Pin 4 CM-GND
Socket 19 – Pin 2 CM-Sensor +
Socket 19 – Pin 3 CM-Sensor -
Socket 19 – Pin 4 CM-GND
Socket 2 – Pin 1 +12 V (A) (output)
Socket 2 – Pin 2 Serial Interface: RxD_0
Socket 2 – Pin 3 Serial Interface: TxD_0
Socket 2 – Pin 4 GND
Socket 20 – Pin 2 CM-Sensor +
Socket 20 – Pin 3 CM-Sensor -
Socket 20 – Pin 4 CM-GND
Socket 3 – Pin 1 +12 V (B) (output)
Socket 3 – Pin 2 Serial Interface: RxD_B
Socket 3 – Pin 3 Serial Interface: TxD_B
Socket 3 – Pin 4 GND
Socket 4 – Pin 1 +12 V (C) (output)
Socket 4 – Pin 2 Serial Interface: RxD_C
Socket 4 – Pin 3 Serial Interface: TxD_C
Socket 4 – Pin 4 GND
Socket 5 – Pin 1 +12 V (C) (output)
Socket 5 – Pin 2 Switch 1
Socket 5 – Pin 3 Switch 2
Socket 5 – Pin 4 GND
Socket 6 – Pin 2 Profibus: a (internal)
Socket 6 – Pin 3 Profibus: b (internal)
Socket 7 – Pin 1 +12 V (Power Supply)
Socket 7 – Pin 4 GND (Power Supply)
Socket 8 – Pin 1 Multi Mode Input 4
Socket 8 – Pin 2 Multi Mode Input 1
Socket 8 – Pin 3 +8.2 V (output)
Socket 8 – Pin 4 GND
Socket 9 – Pin 1 Multi Mode Input 5
Socket 9 – Pin 2 Multi Mode Input 2
Socket 9 – Pin 3 +8.2 V (output)
Socket 9 – Pin 4 GND

Global Certifications

Types Europe: ATEX
Types U.S.: MSHA
Types More certifications on demand
Types Australia: IECEx, ANZEx
Types China: MA
Types Russia: GOST

HEALTH for Longwall Vibration Analysis

Provides vibration monitoring functionality for longterm health monitoring of the following longwall related equipment: • CST gearbox and relating motor • UEL gearbox and relating motor
Provides vibration monitoring functionality for longterm health monitoring of the following longwall related equipment: • Shearer haulage and ranging arm gearboxes • Water/HFA pump station
Provides vibration monitoring functionality for longterm health monitoring of the following longwall related equipment: • Stage loader gearbox and relating motor • Crusher and relating motor

PMC-D Dimensions and Plug Assignments (Approximate)

Height 148.0 mm
Length 335.0 mm
Width 278.0 mm

PMC-D20 Dimensions and Plug Assignments (Approximate)

Height 125.0 mm
Length 335.0 mm
Width 279.0 mm

Electrical Data

Supply Current – Maximum Ratings 1.5 amps
Supply Current – Typical Value 1.0 amps
Supply Voltage – Maximum Ratings 9.5 V - 13.2 V
Supply Voltage – Typical Value 12 V DC

Environmental Data

Temperature – Maximum Ratings -20° C - +40° C (-4° F - +104° F)
Temperature – Symbol Tamb
Temperature – Typical Value 20.0 ° C

Attributes of PMC-D/PMC-D20 Control Unit

  • Robust stainless steel design
  • Highly reliable OS37 plug technology for complete gear box control
  • SKK24 hose cables for bus system and additional I/O connection
  • IP 68 rating (48 hr @ 1 m [3.28 ft] under water)
  • HMI with 24 multi feedback keys (pressure point, led light)
  • 63.5 mm (2.5 in) graphical monochrome display
  • Multi language support
  • Maintainability (brass bar mounting)
  • Optional eight (8) additional ports for acceleration sensors (PMC-D20)

Exemplarily System Layout of a PMC-D System (Shearer Face)

Main Features PMC-D Drive Control System

  • “Distributed controller Intelligence per drive”
  • Synchronized heavy load start up
  • Soft start up
  • Load sharing between conveyor drives
  • Overload protection
  • Motor braking feature
  • Further used in plow operations:
- Precise position detection - Overload protection

Additional Features

  • Usage of PMC-D for chain tensioning of AFC (front and rear conveyor) and Beam Stage Loader (BSL)
  • In conjunction with Slacktronik direct BSL chain slack control and relating chain tensioning
  • Usage of PMC-D for high accurate plow position control and monitoring
  • Support VFD controlled drive applications
  • Optional integration of “HEALTH for Longwall Vibration Analysis” function with PMC-D20 control unit:
- Acceleration sensor interface for 8 sensor - Integrated communication for vibration analysis
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