Joy Powered Roof Supports

Longwall systems

Joy Powered Roof Supports

  • Ratings up to 1,750 tonnes
  • Widths of 1.5, 1.75, and 2.05 meters
  • Heights from 0.8 to 7.8 meters
  • Leg bore sizes ranging from 125 to 480 mm
  • 15,000 to 90,000 cycles versions available
  • Integrated RS20S electronic control system, providing full face automation
  • Integrated Compak hydraulic control system for multifunctional controls

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Joy powered roof supports, for high-capacity longwall applications, are custom designed to meet your exacting cycle and operating requirements:

  • Ratings up to 1,750 tonnes 
  • Widths of 1.5, 1.75, and 2.05 meters
  • Heights from 0.8 to 7.8 meters
  • Leg bore sizes ranging from 125 to 480 mm

Industry leader

  • Over 60 years of experience in designing and manufacturing powered roof supports 
  • ISO 9001 approval
  • CE Certification
  • UKAS Accreditation Testing Laboratory
  • Electronic and hydraulic SIL-rated products

State-of-the-art design process

The Joy design process includes:

  • Finite element analysis (FEA)
  • Fatigue analysis
  • Prototype static and dynamic load testing

This analysis and testing allows for optimized hydraulic efficiency to maximize flow and minimize pressure drops and turbulence, keeping support cycle times to a minimum.

In addition, the structures undergo overload tests of up to 20% and are fatigue tested at twice their rated load. The structural design of the powered roof supports is respected throughout the mining industry for attention to key fabrication details:

  • High-strength steels
  • Automated welding for increased weld integrity
  • Elimination of stress-prone transverse welds

Robust leg construction

  • 125 to 480 mm leg bore size range available
  • Single, double, and triple telescopic designs available for maximum open-to-closed height ratios
  • No welds on leg cylinder for high fatigue life
  • Internal seals work with cylinders for extended service life between rebuilds
  • Patented locking system for leg feeds
  • Extruded design with improved leg geometry for closer positioning to the vertical in a given seam height, resulting better load application to the mine roof
  • Large capacity feeds for large-bore diameter legs requiring high flow
  • High cycle times to match shearer cutting rates
  • Elimination of stress risers

Superb load-bearing capabilities

  • Robust load input area at end of legs using four large steel castings
  • Memory flexible inserts used around leg interfaces keep areas free from debris build up that can lead to bending loads

Compak valve system

  • Multifunctional control with solenoid-actuated pilot circuits receiving instructions from either the operator bush button or RS20S Faceboss electronic control system

RS20s Faceboss control system

The RS20s Faceboss system requires no special gate-end computer for control and is the fastest and most powerful shield control system ever supplied by Joy. These systems are globally fitted on the most automated and productive longwalls.

The RS20s Faceboss system is supplied with a complete automation library of over 100 face cutting sequences to suit virtually all conditions. Using shearer initiation with gate-end automation, no operators need to be specifically deployed for shield operation.

Advanced shearer automation

Shearer operation technology allows the programming of fully automated cutting sequences, including gate end turnarounds. Users can create an initial cutting profile and extraction heights using a graphical planner; the machine then uses the plan to automatically replicate the profile until conditions change. The operator can then override control of the roof drum to follow the preferred horizon. Using the new horizon data, the remainder of the cutting sequence is fully automated using the pre-defined extraction heights. This automation enables the most efficient cycle times possible while providing consistency from one day to the next. The system can store over 100 face-cutting sequences to suite virtually all conditions.

Learn how advanced shearer automation can improve your productivity. 

Promixity Detection for Powered Roof Supports

As technologies allow operators to be moved further from the face, it sometimes means that an operator is not always visible to other mine personnel. The personal proximity detection system is specifically designed to address this issue and reduce injuries to longwall equipment operators.

As part of this system, all personnel wear an individually identified tag which transmits radio signals to the Faceboss control system about the operator's position. The mine is able to set the halt and warning zone parameters that best suit their operators and cutting sequences. If an operator is detected within the halt headway of an advancing shield, the shield is stopped and set to the roof.

Learn more about proximity detection for powered roof supports

Flipper Non-Return Valve

The cartridge-style construction enables ease of assembly adn disassemby in and out of its housing. The valve has been been endurance tested to a minimum of 30,000 cycles in a UKAS accredited test laboratory and overload tested at 1x, 2x and 2.5 x system operating pressure of 345 bar. The stainless steel and high tensile brass construction makes the valve extremely durable and is directly interchangeable with previous designs. 

Learn more about the flipper non-return valve. 

Aftermarket services available

Roof support reconfiguration

Throughout the life of a mine, the operational parameters for the powered roof supports can change. For example, the working height may reduce or the density may need to increase. We can work with you to provide cost-effective alternatives to buying new supports, such as roof support reconfiguration - backed up with an original equipment manufacturer's warranty.

Learn more about our reconfiguration services.

Extended life services

Extended life testing is a process used to evaluate the life left in powered roof support structures. It is a predictive tool that can determine when individual components are likely to reach the end of their serviceable life. This testing allows us to provide you with information that can be used to plan future maintenance budgets with a high level of accuracy; this information may suggest upgrade options, features and solutions to enhance the productivity of your supports.

Learn more about our extended life services.