Bolter Miner -016
Bolter Miner -016
TABLE OF CONTENTS 1 TECHNICAL DESCRIPTION 1.1 General 1. Technical data 3 1.3 Dimensions of the machine 6 1.4 Cutter head profile 6 MACHINE CONCEPT - MAJOR COMPONENTS 7.1 Cutter module.1.1 Gear box 9. Slide frame 10.3 Loading equipment 11.3.1 Gear box 1.4 Chain conveyor 13.5 Track equipment 14.5.1 Track transmission 15.6 Frame 16.6.1 Rear stabiliser (stab jack) 16.7 Electric system 17.7.1 Electric Drive 17. Hydraulic System 1.9 Bolting System 19 Important information! WARNING Read and understand all safety messages and the contents of this operating manual in its entirety. Manuals explain residual risks related to this machinery Ignoring safety instructions could result in serious injury or death. Before machine operation, maintenance, repair or transportation, users MUST understand and adhere to the instructions of this manual. -16 May 011 Page 1
1 TECHNICAL DESCRIPTION 1.1 General The machine was designed for rapid entry roadway development. It is basically a widehead Continuos Miner incorporating special design features with regards to coal cutting and loading. Bolting rigs are an integrated part of this machine. The layout of the machine allows space for 4 roof bolters and rib bolters. All drill rigs as well as the rib bolters are placed immediately behind the cutter-drum. The new design enables a simultaneous cutting- and bolting operation (refer to attached drawing: cutting and bolting sequence). In order to optimize the conditions for operators and face crew the machine is fitted with an onboard dust collecting and scrubbing system. The emphasis is an integration of well proven technology into one machine which gives better advance rates. The machine features are as follows: Simultaneous cutting and bolting operation. Low rotation speed of the cutter-drum and high installed power, to reduce dust development to a minimum. Onboard rib bolting and roof bolting rigs. The loading- and conveying unit moves independently from the cutting device in order to achieve best loading efficiency. Fully shielded extendable bolting platforms for optimized ergonomics. Rib protection for bolter operators safety. Electronic controlled sump- and shear-movement to optimize the cutting sequence as well as the work of the cutter motor. Radio-remote control system for all functions - except drilling operation. Radio-remote control AS 440 compliant. Optional data logging system. Fully integrated water spraying system. Low ground pressure of crawler tracks. No movements of crawler tracks during sumping action (therefore no destruction of floor in soft conditions). Fully supported roof for operators safety,due to support-canopy behind the cutter-drum. Fully automated greasing system for low service requirements. -16 May 011 Page
1. Technical data General 1 Serial No.: 016 Total weight t approx. 97 Total installed power (at 1000 [V], 50 [Hz]) kw 547 Overall length mm approx. 11000 Cutting width in operation mm 500 Cutting height, max. mm 3500 Cutting height, min. mm 900 Machine overall tramming height mm 700 Machine overall tramming width mm 400 Max. width of crawler tracks mm 96 Machine ground pressure N/cm² Ground clearance mm 310 Navigable Area of Application Cone radius, min. m approx. 5 Basin radius, min. m approx. 5 Maximum cross grade ability / gon ±4 / ±5.6 Slope upgrade / incline without stabilizing / gon ±1 / ±0 Loads to be applied Maximum vertical load to the drum [tons] 10 Maximum vertical load to the end of swivel conveyor [tons] 1 Towing at the lugs (machine rear plate LH, RH) [tons] 15 each Cutting system - widehead drum Miner Shape for profile Rectangular Drum width mm 500 Drum extension, hydraulically operated mm x 00 Drum diameter mm 1150 Cutting speed m/sec 1.5 Sumping speed, variable mm/sec 0 50 Max. vertical cutting (shearing) force kn 300 Cutter motor, installed power kw see electrical system Sumping aid (longitudinal slide) mm 1000 1 All dimensions and technical data are theoretical figures. The values are within the usual tolerances. Without dust scrubber. -16 May 011 Page 3
Bolting system Distance roof support to face mm 16 Distance drill rig: face (centre) mm 1490 Distance between centre bolts mm 900 No. of bolts / W. strap - Bolt length (single pass) mm 100 or 400 Rib bolting Bolt type Drilling Support canopy left and right Chemical Rotating Total force supplied to the roof kn x 00 Loading system Loading device Spinners Loading capacity t/min 5 Loading width mm 470-500 Loader motor, installed power kw see electrical system Retraction facilities mm x 465 Conveying system Conveyor width mm 760 Conveyor chain speed m/sec.1 Conveyor capacity t/min 5 Conveyor overhang mm 3000 Conveying capacity t/min 5 Conveyor motor, installed power kw see electrical system Tramming Tramming speed, variable [m/min] 3.5 / 7.0 / 17.0 Ground clearance mm 310 Ground pressure N/cm² Track pulling force kn x 400 Track overall width outside od the tracks mm 96 Track length on ground mm 3400 Track chain width mm 570-16 May 011 Page 4
Dust suppression External sprays for dust supprension. Integrated dust collection and vent duct. Hydraulic system Hydraulic motor, installed power kw see electrical system Pressure max. bar 50 Filtration system, back flow filter and pressure filters Tank capacity l 450 Filler pump kw see electrical system Electrical system Electric potential [V] / [Hz] 1000 / 50 Radio remote control Installed power: standard Cutter motor kw 70 Hydraulic motor kw 13 Loader motors kw x 36 Conveyor motors kw x 36 Filler pump kw 0,75-16 May 011 Page 5
1.3 Dimensions of the machine ALPINE BOLTER MINER 3 656.56000.03 A 1.4 Cutter head profile The cutting height is always depending on the bolting height, you can never cut higher than you can install roofbolts. 3 All dimensions and technical data are theoretical figures. The values are within the usual tolerances. -16 May 011 Page 6
MACHINE CONCEPT - MAJOR COMPONENTS The machine is designed for rapid roadway development in lower seams reaching from 900 mm up to 3500 mm seam high, allowing high advance rates while remaining at face for efficient long-wall development drivage. It is electrically powered. Optimum comfort and safety for operators are provided due to fully shielded cutting area. 6 1 3 11 13 5 1 17 9 14 16 7 10 15 4 1 1 Cutter boom with E-Motor 10 Rib bolter front/rear Cutter drum with gear box 11 Ventilation duct 3 Slide frame 1 Electric equipment 4 Apron with drives 13 Hydraulic equipment 5 Frame 14 Water supply 6 Chain conveyor 15 Roof bolter 7 Track 16 Multi line lubrication unit Stab jacks (rubber bumper) 17 Canopy jack 9 Canopy 1 Wishbone -16 May 011 Page 7
.1 Cutter module The cutter assembly comprises the cutter boom, the cutter motor, the cutter gear and the cutter drum. The cutter boom is a single piece solid steel structure. The gear box is a spur-bevel-planetary drive arrangement. The cutter drum end sections are extendible by 50 mm each side, item 7. Max. penetration (dinting) from the level 1000 mm. 7 3 4 10 5 11 1 9 1 6 Separating Line 1 11 7 1 Cutter boom Gear box 3 Bearing, cutter boom 4 Lifting cylinder, cutter boom 5 Motor cover, E-Motor 70 kw 6 Cutter drum, central part 7 Drum extension, right/left Cutter drum, lateral part 9 Bolt connection, central part 10 Bearing, lifting cylinder 11 P.t.o. lateral part, right/left 1 Bearing, cutter boom -16 May 011 Page
.1.1 Gear box The gear consists of two spur wheel steps, one bevel gear step with intermediate wheels and two planet gear step on each drive side. Technical data Power kw 70 Motor speed, 50 [Hz] [rpm] 140 Input torque Nm 1750 Gear transmission ratio i 57.6 Driven shaft speed [rpm] 5 Output torque [knm] 100 Gear oil quantity l 110 Weight kg 900 All mating surfaces are sealed by suitable sealing compounds (Loctite) against oil penetration. The driving shaft bearing is provided with shaft gaskets, the driven shaft bearing is sealed with rotating mechanical seal. -16 May 011 Page 9
. Slide frame (Sumping frame) The horizontal slide frame allows sumping of the cutting unit together with the conveyor, independent from the main frame thus enabling simultaneous cutting and bolting. 9 7 4 Fitted with Brass bushes to slide on the sumping guides bolted to the main frame. The sumping frame carries: Cutter boom base and the vertical shear cylinders. 5 1 3 6 6 Chain conveyor which is connected with the loading apron. The sliding support for the conveyor allows the movement of only 0.55 m for the loading apron and the chain conveyor. The sumping frame is moved via the sumping cylinder, connected to the sumping frame and the main frame. Also mounted on the sumping frame is the boom level synchro, it informs the micro processor any time of the exact position of the cutter boom. 1 Slide frame Bearing, cutter boom 3 Bearing, sump cylinder 6 Slide bearing for guide rods 7 Ledge of grease points Guide rods 4 Bearing, lifting cylinder 5 Sliding stone, conveyor -16 May 011 Page 10 9 Position sensor for cutter boom
.3 Loading equipment The loading assembly comprises the loader apron, two loader-conveyor transmissions and two spinners for gathering the material. The loading assembly moves forward when the cutter drum is sumped in, this guarantees best loading efficiency. The gathering-conveyor system is driven by two electric motors (36 kw each) via bevel-spur gear transmissions. 3 7 1 4 9 6 5 1 Loader apron Loading stars (spinners) 3 Extension left 4 Extension right 5 Gear box 6 E-Motor, x 36 kw 7 Roller Lifting clyinder 9 Extension cylinder -16 May 011 Page 11
.3.1 Gear box The loading drive is a combination of a spur gear and a bevel gear. Each gearside is driven by one electric motor. The electric motor of the right gear side must turn counter-clockwise, that of the left gear side must turn clockwise. Loader transmission 1 Loader transmission right 4 1. Spur gear. Bevel gear 3. E-Motor, 36 [kw] 4. Loader star 3 Technical data Nominal power kw 36 Revolution [rpm] 1440 Nominal input torque Nm 39 Output speed U/min 4,5 Nominal output torque 70 Output torque, max. Nm 50000 Ratio, i 9,675 Oil volumne l ca. 15 Viscosity 40 C cst 30-16 May 011 Page 1
.4 Chain conveyor The conveyor is rear driven by two 36 kw electric motor with the gear box positioned on the rear end of the conveyor. The vertical movements are performed by two hydraulic cylinders. The horizontal movement is performed by one hydraulic cylinder. The chain is a standard 3 pitch x 9.0 [in] wide continuous Miner flight chain. 9 3 4 5 6 7 1 1 Front part Rear part 3 Swivel part 4 Driving station 5 Lifting cylinder, x (vertical) 6 Swivel cylinder (horizontal) 7 Slidestone conveyor Chain 9 Tensioning device -16 May 011 Page 13
.5 Track equipment The crawler track assembly is of rugged design to suit toughest mining conditions and is totally enclosed to keep out dirt. Each of the track assemblies consists of take-up pulley, take-up sprockets, drive sprocket, drive unit and crawler. The centre part of the track assembly moves on wear-resistant slides. The crawler system is driven by two hydraulic motors with multiple disk brake which is hydraulically released. In case of a hydraulic pressure drop the brakes immediately respond and bring the MINER to a standstill. Traction force [kn/track] 300 Tramming speed, variable [m/min] 5,5 or 11 The track chains are tensioned via cylinders. 6 9 (1) 3 4 5 7 (1) Frame Track frame right/left 3 Guide bar right/left 4 Stabiliser 5 Hydraulic motor 6 Gear with brake 7 Track chain Deflection roller 9 Drive sprocket -16 May 011 Page 14
.5.1 Track transmission The hydraulic motor is directly flanged to the gear. Power drive over two spur gears and two planetary gears. Technical data Input power kw 59 Input speed [rpm] 70 to 1740 Input torque, max Nm 550 Gear transmission ratio, i 10,64 Output speed [rpm] 4. 9.6 Output torque, max Nm 99000 Gear oil quantity l 15 Weight kg 353 Track transmission -16 May 011 Page 15
.6 Frame The frame is a one piece steel structure. It carries all other assembly groups. 3 1 5 4 1 Frame Track frame right/left 3 Sump cylinder 4 Rear stabiliser 5 Guide bar.6.1 Rear stabiliser (stab jack) The supports are integrated in the deflector. It stabilises the machine during cutting and prevents collisions with other vehicles. The supports on the right and left side can be individually lifted and lowered with the aid of hydraulic cylinders. The stabiliser jacks base are 1600 mm, the stroke is 530 mm. Maximum limit under floor 300 mm. The purpose of the stab shoe is to transfer machine 1 weight to the front of the machine to assist in shearing down into the face. In addition, it provides solid support for the rear of the machine which will attempt to lower during the shear down cycle. The stab jack can also be used as a service jack to raise the machine for maintenance. 1. Cylinder. Skid -16 May 011 Page 16
.7 Electric system The electrical equipment is designed to FLP standard. The electric equipment of the, is designed to work on 1000 [V] / 50 [Hz]. The electric equipment is based on the application of the protective conductor system. All parts of the electric system which have body contact are connected with a protective conductor. All switch gear are placed in a flameproof (FLP) enclosure (machine distributor) to where motors, lightening, intrinsically safe control system and trailing calbe are connected to. The electrical equipment incorporates latest technology with respect to health monitoring, sumping speed control depending on current draw of cutter and loader drives, profile control system etc., radio remote control system, optional methane monitoring..7.1 Electric Drive All drive motors are of 3 phase squirrel cage type and direct on line started, which requires stable power supply. Application Cooled Power kw Cutting drum water-cooled 70 Hydraulic drive water-cooled 13 Conveyor drive water-cooled x 36 Loading drive, x water-cooled x 36 Filler pump air-cooled 0,75-16 May 011 Page 17
. Hydraulic System The hydraulic unit of the ALPINE BOLTER MINER comprises of the unpressurised hydraulic tank, the piston-pump group, the control system, the accessories as well as the pipe lines. 5 4 3 1 6 7 9 10 The hydraulic system operates with open circuits. The standard hydraulic components are designed for hydraulic oil. The hydraulic power pack is driven by one 13 kw electric motor. The bolting equipment comprises: 1 Hydraulic tank Breather filter 3 Pump combination 4 Coupling 5 E-motor 6 Pressure filter 7 Filter indicator Back flow filter 9 Heat exchanger 10 Solenoids The system comprises four independent circuits: working circuit 1 (cylinder grease pump), working circuit (water pump), left and right tramming respectively drill rig circuits. The hydraulic motor and cylinders are controlled via spool valves (solenoid operated). -16 May 011 Page 1
.9 Bolting System The bolting system comprises four roof bolting rigs and two rib-bolter which allows rapid advance with simultaneous cutting and roof bolting and rib-bolting. The roof bolters are mounted on joints providing a wide range of bolt placements across the roadway width. 7 4 1 6 3 1 5 5 For conventional continuous miners it is difficult to sump in with crawler tracks if the coal is hard. Therefore the uses the support canopy to hold the machine in position while sumping the drum into the face per controlled cylinder force. The canopy also increases safety for operators. (For detailed description see chapter10, Anchor bolting system). The bolting equipment comprises: 1 four roof-bolters 5 two floor pads two rib-bolters 6 two working platforms 3 stabilizing system with two canopy jacks 7 two control panels for roof bolting four control panels for rib bolting 4 support canopy -16 The roof bolting rigs can be tilted east- and west, plus north- and south. The rib-bolters are located at the working platforms in the back of the operator. The rib-bolters can be tilted up and down to put bolts at various heights. May 011 Page 19
Sandvik Mining and Construction G.m.b.H., Alpinestrasse 1, A-740 Zeltweg, Austria www.miningandconstruction.sandvik.com -16 May 011 Page 0