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Bring your Dragline to the Office

Real-time Production, Analytical, and Video Data

[Still looking for a picture of another dragline]

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Electrical Field ServiceExclusively

in theMining Industry

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•Tyler, Texas, USA

•Bogata, Texas, USA

•Casper, Wyoming, USA

•Gillette Wyoming, USA

•Edmonton, Alberta, CAN

•Dubois, Wyoming, USA

•Lakeland, Florida, USA

•Moranbah, Queensland, QLD

•Emerald, Queensland, QLD

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Introduction

DCS is a mining service organization specializing in electrical engineering applications on mobile mining apparatus. In addition to providing ongoing scheduled and emergency service, we perform PLC, drive and monitoring system upgrades. We are an organization with a global focus and are committed to providing quality mining services.

In today’s global economy and competitive marketplace, mine operators areconstantly seeking ways to enhance machine performance. Increasing machine production and reducing maintenance costs are the primary goals of today’s successful miners.

Access to real-time information relating to excavator performance and productivity is of paramount importance. Through application of digital control and wireless communication technology bringing field data into the local office or headquarters a thousand miles away, these goals can be achieved.

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Today’s Presentation

• Establishing a Wireless Network• PLC Based Production Monitor• Accessing Production Data Remotely• Remote XY Recording• Remote PLC Monitoring and Edits

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Establishing a Wireless Network

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PLC5 Controlnet Upgrade

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SLC5/04 Control System Upgrade

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Operator Interface (Panelview)

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Block Diagram

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About Ethernet Wireless…

• Frequency hopping spread spectrum• Versatile modes of operation• No license required• Compatibility with office networks• Compatibility with PLC control networks• High data throughput• Limited range• Line of sight must be maintained

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The Modems• AB Encompass partner• High # of frequency channels• 900MHz band, better data integrity&range• Good operating specs• Good tech support• Field proven

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The DCS Real-time Production Monitoring & Reporting System

-The DCS dragline production monitoring and reporting system can access a snapshot of detailed production information from any dragline on site via wireless communication systems.

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DCS DRAGLINE PRODUCTION MONITORING

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REPORTING SYSTEM

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DCS Production Monitoring and Reporting System

• Program is PLC based• Operator Interface via AB Panelview or existing MMI• End of shift, demand reports, or live data summaries are

displayed and archived via Microsoft Excel• All component parts of the system are industry standard

and commercially available• Production monitoring can be integrated into all DCS

control and annunciation packages requiring minimal additional hardware

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How it Works…

• Running suspended load test by monitoring hoist line pull (each bucket weighed individually)

• Algorithm calculates motor torque for variable armature and field current

• Samples and averages weight at PLC scan rate (typically 15 to 20msec)

• Program considers bucket carryback• Program considers rope acceleration factor• Program considers off vertical factor and

tightline effect• All individual loops and motor fields monitored

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System Hardware Requirements•Allen Bradley SLC5/04 PLC, analog and discrete input cards, resolverinput cards

•Allen Bradley Panelview

•Hoist and Drag armature amps transducers

•Hoist motor field amps transducer

•Hoist, Drag, Swing position resolvers

•Propel/Dig status contact, power on status (if PLC is UPF supplied)

•Office grade PC running Microsoft Excel 2000 and Allen Bradley RSLinx

Optional

•Onboard printer

•RF serial modems to link PC in office to PLC on dragline (or PC to PC)

•Ethernet bridge to link on board PC to office network

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Hoist, Drag, and Swing Resolvers

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Isolators and Signal Conditioning

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Features of the Operator Interface•Displays real time shift quantities and averages to the operator through a series of graphic display screens

•Allows the operator to compare current shift data to history

•Requires the operator to input her/his ID number and dig, delay or down code

•Displays screen to signify end of shift and prompt operator for ID and dig delay or down code

•Will annunciate to the operator if any of the following conditions occurs

- no activity entered and the dragline is digging

- no down or delay code entered and the machine is not digging

- prompts for valid outage code once power has been restored following an outage

- no operator ID entered

Note: all unallocated time is captured as unidentified digging, unidentified down or unidentified power outage time.

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Production Monitor Main Menu

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Production Totals Screen

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Cycle by Cycle Feedback

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Step Counts Screen

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Sensors Screen

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Bucket to Bench Level

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Comparison Data

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Enter Codes and ID

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Operator Warnings

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Reporting System

• MSExcel based• Captures PLC data via DDE using any AB

driver into onboard PC• Programs for trapping shift end, demand or

realtime data are written in VBA (Excel macros)

• Raw data saved as *.xls file• Custom reports/queries application specific

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Production Data

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Delay & Down Codes

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Real-time Production Data Analysis

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Real-time Data Analysis-The excavator data acquisition system developed by DCS is an excellent tool for assessing machine drive systems and maintaining peak performance.

-The system is capable of simultaneous monitoring up to 16 channels single ended or 8 channels differential of real-time data.

-This system can now be integrated with any DCS excavator PLC-based control system to access live XY data and brush recordings through wireless Ethernet or spread spectrum serial modems. In this way machine condition monitoring can be conducted in a central mine location or remote from the mine site.

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Advantages of Remote XY and Chart Recording

• Assess performance of all minesiteequipment from a central location

• Troubleshoot equipment problems remotely• Access data from off site through dialup• Improved safety for acquisition of data

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Remote XY Software (beta)

• Delay time in TCP/IP packet turnaround• Data buffered in PLC• RSLinx DDE block reads by Labview• Once block is read poke word back to PLC to

clear buffer and reinitiate fill• Approx. delay of 3 to 5 seconds with 19.2k

phone line• Final version software will tune ping and buffer

feed rates to display best XY resolution (17 to 20 hz optimul)

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Real-time PLC MonitoringThe DCS excavator control systems can be accessed remotely for performing online PLC monitoring and edit functions.

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Real-time Video Data

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ConclusionAccess to real-time information relating to excavator performance and productivity from remote locations are primary goals of today's successful miners. This information allows miners to respond to deficiencies in operating or control system performance in an expeditious way. Through application of digital control and wireless communication technology these goals are achievable. Access to real-time critical information from virtually anywhere in the world will provide for a competitive advantage.

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