Joy introduced the first all-electric shearer in 1976. Since then, Joy shearers have been working in the world’s most productive longwall mines and in the most demanding conditions. Models are available for seam ranges from 1.3 to 9.0 meters (4.3 to 30 ft.). In addition, the series has a complete series of installed ranging arm power options available, ranging from 300 to 1100 kW (402 to 1475 hp).
Joy shearers are designed to be robust, provide high availability, and feature a modular design. The body consists of a controller case and two haulage cases to form a rigid structure with no underframe. The two ranging arms feature gears designed and produced by Joy using propriety processes that play a crucial role in maximizing performance.
The Faceboss control system, featured on Joy underground mining equipment, helps maximize productivity and features a powerful tool set including advance diagnostics and user friendly, multi-lingual displays. Optional features like advanced shearer automation assists operators in maximizing productivity by programming cutting profiles and gate end turnarounds.
Modular design
The longwall shearer’s modular design consists of five main structural components:
- Body: consists of three high-tensile steel fabrications bolted together to form a slim main section with no underframe; this design provides maximum underbody clearance for material passage in a given seam thickness and also makes underground transportation easier.
- Controller case: centre section which contains the electrical control system; design features gob-side access to the electrical controller section and motors, which means that normal maintenance can be carried out in a safer working environment.
- Traction sections (2): bolted and doweled to each end of the controller case. The down-drives are bolted to the traction cases in an arrangement that permits the custom fitting of the shearer within the armoured face conveyor and roof support envelope; a wide selection of down-drives can be fitted to the shearer to suit both mining conditions and the armored face conveyor selected.
- Ranging arm: high-tensile steel cases house the cutter motors and gearcases. Ranging arm cylinders are made using the same technology as our powered roof supports. These cylinders have double the pressure rating when compared to industry norms. In-house manufacture of bit holders and cutter drums allows for a higher degree of integration and machine performance. Gearing is designed using proprietary processes, which contribute to maximum performance.
The modular construction of our longwall shearers also allows for efficient manufacture and rebuilds. Our shearers are designed to be as simple and easy to maintain as possible, with special tools rarely required. In addition, the cowl-turning mechanisms are integrated into the ranging arm design, creating rugged components that require little maintenance.
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Cutting height
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Machine height
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Machine weight
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7LS0
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1.3 to 2.0 m
51 to 80 in.
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890 mm
35 in.
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45,000 kg
100,000 lbs.
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7LS1A
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1.5 to 3.0 m
4.9 to 9.8 ft.
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1.0 to 1.3 m
3.3 to 4.3 ft.
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46,800 kg
103,000 lbs.
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7LS1D
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1.5 to 3.9 m
4.5 to 9.8 ft.
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1.0 to 1.3 m
3.3 to 4.3 ft.
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52,000 kg
115,000 lbs.
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7LS2A
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1.6 to 3.5 m
5.2 to 11.5 ft.
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1.0 to 1.3 m
3.4 to 4.3 ft.
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59,000 kg
130,000 lbs.
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7LS3A
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2.0 to 4.0 m
6.6 to 13.1 ft.
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1.45 to 1.7 m
4.8 to 5.6 ft.
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60,500 kg
133,000 lbs.
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7LS5
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2.0 to 4.5 m
6.6 to 14.8 ft.
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1.5 to 1.9 m
4.9 to 6.2 ft.
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81,700 kg
180,000 lbs.
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Haulage pull
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Pump
motor power
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Haulage
motor power
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Lumpbreaker
motor power
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Maximum cutting
motor power
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7LS0
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626 kN
120,000 lbs.
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1@20 kW
1@27 hp
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2@60 kW
2@78 hp
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N/A
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2@335 kW
2@448 hp
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7LS1A
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800 kN
180,000 lbs.
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2@11 kW
2@15 hp
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2@65 kW
2@87 hp
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N/A
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2@600 kW
2@804 hp
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7LS1D
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800 kN
180,000 lbs.
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2@11 kW
2@15 hp
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2@65 kW
2@87 hp
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N/A
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2@600 kW
2@804 hp
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7LS2A
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800 kN
180,000 lbs.
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2@11 kW
2@15 hp
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2@80 kW
2@107 hp
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55 kW
74 hp
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2@675 kW
2@905 hp
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7LS3A
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800 kN
180,000 lbs.
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2@11 kW
2@15 hp
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2@80 kW
2@107 hp
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55 kW
74 hp
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2@675 kW
2@905 hp
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7LS5
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800 kN
180,000 lbs.
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1@20 kW
1@27 hp
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2@110 kW
2@148 hp
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130 kW
174 hp
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2@750 kW
2@1005 hp
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Faceboss control system
Competitive and market pressures mean that you have to produce product at an ever-increasing rate, while always striving to decrease your cost per ton. These goals are only made more difficult by the worsening attributes of available reserves and deteriorating operating conditions.
The Faceboss control system enables your operators to operate equipment at an optimal balance of production rate and cost per ton using a powerful tool set that includes operator assistance tools, automated sequences, advanced diagnostics, machine performance monitoring, and analysis tools. Faceboss is the standard control system platform on all Joy underground mining equipment, which ensures that you receive the same level of optimisation for all your Joy equipment.
Faceboss maximises your longwall shearer productivity in a variety of ways:
- Optimised cutting: The cutting rate is automatically maximised during cutting cycles, ensuring optimal cutting and loading, through the control of the traction motor speed
- High-availability feedback: Control loops protect all electric motors from jam and thermal overloads to extend motor life and minimise machine downtime
When your longwall shearer is connected to a surface computer, Faceboss allows real-time monitoring of the machine from remote locations (remote machine monitoring, or RMM).
Learn how Faceboss can help improve your productivity.
OptiDrive AC
Joy OptiDrive, an AC variable-frequency drive system, integrates software with the electronic and mechanical systems to provide the following features:
- Regenerative braking: Supplements the mechanical brakes, allowing them to run cooler with extended wear life; regenerative braking is highly effective at automatically maintaining constant speeds when descending gradients
- Better speed control: Provides infinitely variable tram speed capability, allowing precise control of the equipment’s speed
- Less maintenance: No commutator brushes to inspect and replace mean AC traction motors are typically more reliable, more durable, and require less maintenance than DC traction motors
Learn how OptiDrive can help reduce operating costs.
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.
Remote visualisation system
The remote visualisation system provides real-time video, displayed at the Remote Operation Centre, using cameras integrated into the ranging arm chassis. The system features automated water sprays to keep the camera lenses clean and enables the ability to operate the machine from a remote location using a handheld remote.
Radio motion monitoring
Radio motion monitoring (RMM) is a safety feature available for longwall shearers. Through the addition of technology within the remote control unit, motion of the unit is monitored, allowing for the shutdown of the shearer in the event of abnormal or lack of motion. With an integrated longwall system, the shutdown of the shearer also stops the advance of the powered roof supports.
Lumpbreakers
Lumpbreakers, with installed power up to 270 kW, provide a rotating drum on the tailgate end of the shearer to break up any material that may not pass beneath the shearer.
Cowls
The fitment of cowls to the ranging arms maximizes the shearer’s ability to load cut material onto the AFC. When ASA is fitted, cowl operation can be automated, insuring proper location during operation.
Sloughing plates
Sloughing plates, typically fitted to shearer operating in higher seam heights, provide protection from face spalling during operation. With remote control operation, sloughing plates can be adjusted in varying seam conditions.