Applying Sensor-Based Information Systems to Identify Unplanned Downtime in Mining Machinery Operation

Underground mining belongs to immensely complex processes and depends on many natural, technical and organizational factors. The main factor that hinders this process is the environmental conditions in which it is carried out. One of the problems associated with the use of increasingly modern machines in such conditions is the issue of unplanned downtime during their operation. This paper presents the developed methodology and IT system for recording breaks in the operation of mining machines and identifies their causes. The basis of this methodology is a sensor-based information system used to register mining machinery parameters, based on which interruptions in their operation can be determined. In order to register these parameters, an industrial automation system (together with a SCADA system supervising the process) was used, which is practically independent from the operator and enables continuous registration of these parameters. In order to identify the reasons for the recorded breaks, an IT tool was developed in the form of an application in the module of the integrated mining enterprise management support system (ERP system). This application enables (with a continuously updated database) the identification of the causes in question. Thus, the developed solution enables the objective registration of machine downtime and, for most cases, the identification of causes. The acquired knowledge, so far largely undisclosed, has created opportunities to improve the utilization level of machinery exploited in the mining production process. The paper discusses the methodology, together with the IT system, for identifying the causes of machine downtime and presents an example of its application for a shearer loader, which is the basic machine of a mechanized longwall system. The results indicate great potential for the application of the developed system to improve the efficiency of machinery utilization and the whole process of mining production.