Innovative Conveyor Control at Kestrel South

Revolutionizing Longwall Mining at Kestrel South

At Kestrel South coal mine, robust and efficient conveyor systems are crucial for transporting extracted materials. The complex nature of the mining environment has historically posed challenges for maintaining optimal speed and tension on these conveyors.

Customer Challenges

Kestrel South faced several operational challenges with their maingate conveyor:

  • Incorrect torque distribution between drive stations

  • Imbalance in tripper and drivehead tension

  • Fluctuating speed performance under variable loads

  • Issues with VSD current and torque limiting

  • Production interruptions due to slip and tension faults

The conveyor's belt geometry constantly changes throughout the longwall cycle, requiring a more adaptive control solution.

The Breakthrough: Coordinated Speed & Tension Control

DJL Automation introduced a revolutionary solution at Kestrel South: the Coordinated Speed & Tension Control system. This next-generation conveyor control integrates real-time speed regulation with dynamic tension balancing.

How It Works

  1. Calculate Conveyor Torque: Based on speed requirements.

  2. Monitor Belt Tension: Using sensors on the tripper and drivehead.

  3. Dynamic Torque Distribution: Manages speed and torque at both drivehead and tripper.

  4. Continuous Adjustment: Maintains tension and speed within set limits.

This approach ensures accurate and timely torque distribution, enhancing operational efficiency

Key Benefits at Kestrel South

  • Increased Production Uptime: Reduced torque-related trips.

  • Enhanced Safety & Reliability: Maintains critical tension bounds.

  • Intelligent Torque Distribution: Prevents overloading of drive stations.

  • Higher Starting Torque: Instant torque application at breakaway.

  • Flexibility & Scalability: Adaptable across full conveyor lengths and configurations.

Optimal Performance Areas

The control system excels in:

  • Longwall retreat operations

  • Variable belt load distribution

  • Heavy load startups

  • Optimizing control under reduced capacity

Conclusion

The implementation of DJL Automation's Coordinated Speed & Tension Control at Kestrel South has brought modern engineering solutions to the mining industry, ensuring safer, more reliable, and more productive conveyor operations.