Background: A major manufacturer of underground mining machinery needed a means of remotely operating battery powered loaders under the unsupported roof of a coal face.

Project: The initial request was for Product Resources to design a radio remote control. However, during initial discussions Product Resources demonstrated that for an equal investment, the machine could be completely controlled by an on-board computer that would receive driver commands either by radio or by a hard-wired connection. This approach enabled the customer to reduce the cost of the machine by eliminating the conventional operator controls, operating the machine only via the computer in both 'remote' and 'driver on board' modes. The hardware consists of an intrinsically safe operator console containing a microprocessor which encodes the driver's commands into serial data to be transmitted to the machine. On the machine, an STD bus computer decodes the operator commands and produces appropriate electrical signals to operate hydraulic solenoid valves, energize relays, and operate electrical drive speed controls. A comprehensive manual was written by Product Resources to fully document the product and provide an aid for operator training and troubleshooting.

This product has been approved by MSHA as being in compliance with relevant underground mining regulations.

Technologies: software programming in C and assembly languages, communications protocol, embedded microcontrollers, intrinsically safe circuit design, DC/DC converters, microcontroller I/O to hydraulic interface, vacuum-formed plastics, sheetmetal work, CNC machining, silkscreen labels, self-adhesive panel legend overlays, ergonomics, VHF radio digital communication, severe operating environments

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