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Customized Control Solutions for Mining Machinery
Table of Contents
Challenges in Mining Machinery
Mining machinery operates in extreme duty cycles involving abrasive silica dust, persistent moisture, high-impact vibrations, and ambient temperature swings from -40°C to +60°C. These environments demand not only physical robustness but strict compliance with functional safety (IEC 61508 / ISO 13849) and support for increasing levels of semi- and fully automated control.
SonnePower’s controllers, displays, I/O modules, and keypads are designed with industrial-grade electronic components and feature protective coating on PCB assemblies to help resist dust, moisture, and vibration—essential for stable operation in harsh mining environments.
Why Customization Matters in Mining Equipment
High Reliability in Harsh Environments
In rugged scenarios like open-pit or underground mining, control systems must provide reliable sealing and mechanical strength.
Common practices include using IP67-rated controllers, I/O modules, and display terminals. PCBs are coated to enhance resistance to dust, moisture, and vibration.
Some systems remain responsive within milliseconds even after high-intensity vibration tests.
Modular Flexibility and Scalability
Modern control systems are based on CANopen bus (ISO 11898) with a modular structure.
This allows flexible I/O configuration for equipment such as dump trucks, drills, and tunneling rigs.
Support for redundancy, hot-swappable expansion, and programmable logic makes rapid adaptation and upgrades possible.
Lifecycle Efficiency
In remote mines, downtime can cause significant losses—e.g., a large haul truck may incur thousands of dollars in hourly losses.
Some systems integrate remote diagnostics, OTA firmware upgrades, and logic-level redundancy to reduce maintenance frequency and improve MTBF.
SonnePower Control System Components for Mining Machinery
Controller
SonnePower controllers offer a wide configuration range to flexibly meet the complex control requirements of mining and construction machinery:
✔ Wide I/O range – Supports from 4 to 66 I/O channels, covering applications from lightweight control to large-scale centralized control.
✔ Flexible communication interfaces – Depending on the model, supports 2 or 3 CAN channels with expandable bus architecture.
✔ Unified programming environment – Compatible with CoDeSys 2.3 or CoDeSys 3.5, supporting IEC 61131 standard programming.
✔ Rich optional interfaces – Selected models support RS232, RS485, and Ethernet for easy integration with external modules or remote communication.
✔ Analog output support – Advanced models provide AO, PWM, and Vout outputs, ideal for proportional control and analog drive applications.
✔ Adaptable to diverse machinery platforms – Applicable to small electric drive units, AGV node control, and complex tunnel boring machine control systems.
CAN Bus Display
Highlights
🛡 Dust & water resistance up to IP65/IP67
💡 High-brightness displays (≥600 cd/m²), suitable for outdoor environments
🔗 Multi-bus capability (up to 5× CAN)
🎮 Optional physical buttons and capacitive touch
📦 Expandable: 4G / BeiDou / Ethernet / AHD video inputs
🧠 CoDeSys 3.5 support, customizable logic integration
Recommended Display Models for Mining
SPD-070-Fx / Ex series (7")
Resolution up to 1024×600, supports up to 5 CAN + AHD input + capacitive touch
Applications: TBMs, jumbo rigs, central control stations
SPD-050-E (5")
With programmable tactile keys, compact form factor, high brightness
Applications: Haul truck auxiliary screens, cabin side display
SPD-043-B / Ex (4.3")
Smallest footprint, ideal for constrained spaces or embedded terminals
Applications: Small drilling platforms, hydraulic pump vehicles
SPD-080-Fx (8")
Larger display, richer I/O options
Applications: Mine vehicles, electric sprinkler trucks, remote operation cabins
SPD-121-Ax (12.1")
Wide viewing angle and large format
Applications: Remote stations, heavy-duty surface mining equipment
I/O Modules for Mining
SonnePower offers IP67-rated distributed I/O modules tailored to mining applications:
Up to 32 I/O points per module, supporting both analog and digital I/OsSDIO-1412 / SDIO-0032
High-density modules with 26–32 I/Os
Applications: TBMs, drills, dump truck control platformsSPM-SDIO-MD2
Supports up to 35A high-current output
Applications: Work lights, hydraulic valves, power drive controlsSDIO-S0808SPK
Compact layout, integrated voice amplifier
Applications: Space-constrained vehicles, audio alert integration
CANopen protocol across most modules, enabling seamless integration
Designed for chassis-mounted or outdoor modular enclosures
Rugged CAN Keypads for Mining
✅ All models support 1× CAN with user-defined protocols
⌨ Wide range: 8, 12, 16, 17, 20 keys. Models with rotary knobs (B08, D08) available
⚡ Output: Most support 1× DOH
🔹 Status Indicators: RGB mono or tri-color LEDs; some with progress bars (e.g., Q08-D10)
🔦 Backlight: White adjustable brightness, optimized for underground lighting
🌎 Custom legends and membrane overlays available
Recommended Keypad Models
SPM-KEYP-Q08-D10 — Suitable for underground drills or tunneling machines
SPM-KEYP-B08 / D08 — With knob, ideal for multi-axis digging arms
SPM-KEYP-Q16 / A16 / A20 — High-key-count for transport vehicles
SPM-LEDP-C12 — LED-only panel for status and alarm indicators
Electric Motor Solutions for Mining Machinery
Core Features
🔋 Voltage Platform: 336V / 540V / 576V high-voltage DC systems
🔧 IP67 rating for wet, dusty, high-vibration environments
🌡 Liquid cooling for continuous heavy-duty operation
🔊 Insulation Class H, suitable for high-temperature endurance
🛁 Flange mounting for integration with pumps, actuators, electric axles
Recommended Models
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MSP38 Series (for electric pumps)
E.g., MSP38-060S533S080H240 — 60kW, 550Nm, 3000rpm
Applications: Sprinkler trucks, grouting pumps, maintenance platforms -
MSP43 / MSP48 Series
Typical power: 30kW / 50kW / 60kW
Applications: Road cleaning, dust control -
MSP85 / MSP100 High-power Liquid-cooled Motors
E.g., MSP85-100S775X112SH085 — 100kW @ 707Nm
Applications: Mining trucks, drill rigs, loaders, drive subsystems
Conclusion: Build Smarter, Safer, and Tougher Mining Equipment
SonnePower provides field-proven, IEC-compliant control solutions specifically designed for the harsh realities of mining. Our IP67-rated controllers, rugged displays, sealed I/O modules, and customizable keypads form a robust architecture that can be tailored to your machine layout and control strategy.
📈 Contact SonnePower to discuss your mining control requirements
