Roadheader KP25
The roadheader KP25 is designed for mechanization of breaking and loading of rock mass during horizontal and inclined workings of ±12°. improving working conditions at the driver’s workplace. The use of hydraulic motors as a drive for the running gear and the feeder ensures convenience and safety in maintenance and reliability. The hydraulic system of the harvester provides smooth regulation of the feed rate executive body downhole through the use of an adjustable pump, and an autonomous pumping station ensures the convenience of hydraulic system maintenance. mine and transportation through mine workings.
Specifications
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Technical performance: |
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| - for coal, m3/min (t/min) | 2,4 |
| - by breed STszh<100МПа, м3/мин | 0,2...0,3 |
| Specific pressure on the soil, MPa | 0,12 |
|
Chassis: |
|
| - drive unit |
hydraulic |
| - travel speed, m3/min | 6 |
| - pulling force, t | 36 |
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Executive limit: |
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| - cutting speed, m/s | 2 |
| - bit rotation frequency, min-1 | 50 |
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Hydraulic system |
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| - maximum pressure in the hydraulic system, MPa | |
| - working fluid | industrial sectional oil |
| - hydraulic distributors | manually operated |
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Feeder |
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| - drive unit | electric |
| - number of paw swings, min-1 | 46 |
| - feeder width, mm minimum | 2200 |
| - feeder width, mm maximum | 3200 |
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Irrigation system |
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| - working pressure, MPa | 1,5 |
| - maximum flow, l/min | 150 |
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Conveyor |
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| 1,0 | |
| - chute width, mm | 550 |
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Conveyor |
|
| - scraper chain speed, m/s | 1,0 |
| - chute width, mm | 550 |
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electrical equipment |
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| - voltage of power circuits, V | 660
|
| - total power of electric motors, kW | 216,5 |
| - drive power, kW of the executive body | 196,5 |
| - feeder | 110/55 |
| - conveyor | 30 |
| - pumping station | 55 |
| Harvester weight, t no more | 40 |
Reading 5 min.
A tunneling machine is a specialized technique designed to crush rock masses, reload scrap stone into trolleys and other transport mechanisms. The device is used in the development of mine workings located in horizontal and inclined planes, in the improvement of tunnels.
In the mining and coal industry, there is a growing need for specialized equipment that can increase productivity while reducing time. Developments of domestic and foreign manufacturers are aimed at improving and expanding areas of application. A modern mine heading machine equipped with a remote control increases safety and convenience of work.
Classification
The most widespread models are: combine 1GPKS, P-110, KSP-32 and 35, KP-21 of domestic production, as well as tunneling equipment of foreign companies. The model range of special vehicles is classified according to the following factors:
- according to the method of slaughter processing;
- by scope;
- in terms of weight and power.
Based on the method of processing the slaughter, combines are divided into mechanisms of cyclic (selective) action with successively performed processing in runs or layers. Drilling or continuous action devices allow simultaneous bottomhole processing. The second type of equipment includes a mine tunneling combine, which is characterized by high productivity.
According to the scope of application, mining specialists divide equipment into mechanisms, the purpose of which is to cut workings along the seam. Another type of harvester is a device for carrying out preparatory workings when interacting with minerals and weak rocks. For the processing of rocks of medium strength, coal combines have been developed for seams of medium thickness. Such devices perform capital and preparatory workings.
Depending on the power and mass of special equipment, the following types are distinguished:
- heavy, the mass of which reaches 100 tons, and the engine power is 400 kW;
- medium-sized with a mass of 35-50 tons and a power of 100-160 kW;
- light, the mass of which does not exceed 25 tons, and the power characteristics correspond to 60-80 kW.
See » Characteristics and device of the combine harvester Rostselmash RSM 161
All types of tunneling machines have their own characteristics, which must be taken into account when choosing a suitable model of special equipment.
Principle of operation
The mine tunneling combine is a device equipped with an arrow and a milling crown, to which a cutter-type cutting tool is attached. This mechanism allows you to work with the face of various configurations in cross section.
This type of equipment is additionally equipped with nozzles that allow you to perform auxiliary operations - anchoring the roof and sides, lifting the support parts. Hinged elements increase the level of stability of the entire mechanism, help to control the direction of movement. Some models use laser control and software control.
The continuous coal miner is equipped with a working body of a rotary type with a drill bit, on which buckets and cone devices are located. When processing the face with the help of the main equipment, the complete destruction of the rocks is performed. In some cases, it may be necessary to use a cutter that allows you to give an arched shape.
On modern specialized machines, a caterpillar undercarriage is installed, giving increased cross-country ability to equipment.
Model overview
The multi-drive mechanism is designed to perform a complex of operations - destruction, loading, delivery of rock, fixing the working, ventilation, dust suppression. Such functional equipment is produced at Russian and foreign enterprises.
One of the popular models is the roadheader KSP-32, designed for loading and breaking rock masses in the implementation of horizontal or inclined workings. The equipment works with coal, mixed rocks, as well as in conditions of increased formation of methane and coal dust. The control of such a mechanism is carried out using a portable remote control.
The Ural-61 heading and cleaning combine is a high-power equipment designed to form development workings of an arched configuration. This model is in demand due to the possibility of chamber excavation of potassium deposits. The mechanism is designed to operate in a temperate climate at an ambient temperature of +5…+35°C.
The roadheader Joy was specially designed for the Kuzbass mines. The use of semi-automatic drilling mechanisms and a dust extraction system make it possible to increase the safety and comfort of work. This device quadruples the productivity of the mining enterprise.
See » The device and principle of operation of the TOP-5 mini-harvesters for grain harvesting
The roadheader 1GPKS produced by the machine-building institution of the city of Kopeysk is one of the popular models. The purpose of this mechanism is breaking and loading of rocks when working on horizontal and inclined planes up to 12°. In the advanced technique, the degree of inclination has been increased to a value of 25.
High awards at international exhibitions were received by the KP-21 combine, which, thanks to its own technical characteristics, is able to carry out the destruction and shipment of mountain ranges when working in various planes. This model of domestic special equipment is widespread in the international market.
Price and reviews
This type of special equipment requires significant material costs for the acquisition. The possibility of renting allows you to reduce financial losses, minimize the need for additional manipulations, including timely technical inspection and repair, equipment maintenance, and staff training. The rental price varies depending on the volume and timing of the work to be done. Many specialized companies offer special conditions and special programs that allow you to rent combine harvesters on favorable terms.
Ivan Pashkov, 42 years old, Kemerovo: “Working with the roadheader KP-21, I can say that this machine is reliable, allows you to quickly and efficiently cope with the tasks. The technique allows the construction of underground structures, including in an inclined plane.”
Dmitry Mikhailov, 31 years old, Leninsk-Kuznetsky: “The special mining equipment that we use in the development of faces is distinguished by its ability to function in various conditions, maneuverability, and structural simplicity. A variety of such mechanisms is the P-110 roadheader, which has never let us down during its service life.”
Completion of the first stage of structural transformations in the mining industry of the Russian Federation is characterized by a change in the formation of its financial resources, now this occurs exclusively through the sale of industry products.
The period of a long decline in production volumes in the course of the restructuring of the industry has remained in the past, in recent years one can observe a clear upward trend in mining, and changes for the better in the technical and economic indicators of the development of the mining industry. The Government of the country adopted the "Energy Strategy
Russia for the period up to 2020”, which set the task of increasing the volume of coal production to 410-450 million tons per year and increasing the share of coal in electricity generation from 34 to 44%.
In order to fulfill this strategic task by the specified deadline, it is necessary to significantly increase the production capacities of enterprises in the industry.
This can be achieved through the modernization of existing enterprises, as well as the construction of new ones. At the same time, the Government Program provides for the increase in capacity until 2010 through technical renovation, and the period 2011-2020. should be characterized by a fundamental change in the technical level of the production process itself.
As best foreign experience shows, high performance in coal mining can be achieved by concentrating production at promising mines. This process is based on the technical re-equipment of treatment facilities, which leads to major changes in the preparatory work.
And this means that, first of all, such events should affect the most progressive combine method. Today, combine driving at the leading coal enterprises of Kuzbass covers up to 98% of the total scope of work.
In the fleet of mining equipment of the coal industry of the Russian Federation, roadheaders number up to 400 units, of which about 250 are located in Kuzbass. The bulk of the harvesters are GPKS type manufactured by the Kopeysk Machine-Building Plant. Analyzing the state of tunneling equipment, one can state a steady decline in the technical level of the fleet of machines.
The wear and tear of combines at the major coal companies is a warning sign of possible failures in the face of an ever-increasing volume of preparatory work.
Roadheader GPKS
Produced by the Kopeysk Machine-Building Plant. Its purpose is mechanized breaking and loading of rock mass during horizontal and inclined mine workings of coal and rock. Combine 1GPKS-00 in the basic model was intended for horizontal and inclined workings with a slope of up to ± 12°. On the latest modifications of the harvester, devices are already provided that can hold the harvester on slopes up to ± 25 °.
The fleet of roadheaders in the Russian coal industry is mainly equipped with combines of the GPKS model, in particular, in Kuzbass they are up to 97% of the total number of combines.
Tunneling machine P 110
Combine with selective action, has a boom working body, the combine is used for mechanized destruction with subsequent shipment of rock mass. It is used when it is necessary to perform an arched, trapezoidal or rectangular working with a cross-sectional area from 7 to 25 m2. Sinking can be performed with a slope of ±12° in a coal or mixed face with a maximum rock strength of 95 MPa (f=7) and an abrasiveness of about 15 mg in mines where there is a danger of gas contamination and dust.
Roadheader KP 21
Produced by the Kopeysk Machine-Building Plant since 2000, over the past period, only positive reviews have been received about its work. His excellent work was appreciated both in Russia and in foreign countries. Roadheaders KP21 are designed for mechanization of destruction and subsequent shipment of rock mass when horizontal and inclined mine workings are performed.
The KP21 harvester has been presented at a number of international exhibitions and has worthy awards. As one of the best exhibits, he was awarded a diploma and a medal at an exhibition held in June last year in Novokuznetsk.
OJSC "KMZ" and a large Iranian company "Sabir" have established productive cooperation, in March last year, fulfilling the order of this company, a batch of two roadheaders KP21 was manufactured and sent to Iran.
Roadheader KSP 32
Roadheaders of the middle series KSP-32 are designed for mechanized destruction and subsequent shipment of rock mass from the site of horizontal and inclined mine workings up to ±12 degrees.
The cross section of workings can reach up to 33 square meters. m with coal sinking and mixed slaughter. It is allowed to work in conditions with a tensile strength of the destroyed rock up to 95 MPa (f = 8) and an abrasiveness up to 15 mg in mines where there is a danger of gas contamination (methane) and coal dust.
Roadheader KSP-32 is controlled from a portable remote control. The harvester was designed and manufactured in 1998 at the Yasinovatsky Mashzavod enterprise in Donetsk.
Roadheader KPD
It is intended for the destruction of rock, with subsequent cleaning and transportation of the destroyed rock mass during the excavation of development workings. The cross section of workings in shape can be arched, trapezoidal and rectangular in size from 11 to 25 m2.
The design features that the harvester has are an arrow-shaped telescopic type of the executive body, on which the axis of transverse rotation, this device allows you to effectively destroy rocks and at the same time ensure a stable position of the harvester;
it is possible to install electric motors of different power on the executive body, which makes it possible, depending on the strength of the destroyed rocks, to choose the most cost-effective cutting mode;
the loading body, made in the form of rowing stars, shows a high intensity of loading, it is possible to work effectively in flooded workings.
Roadheader EBZ 160
It is used for work in mine workings for coal, for mixed slaughter, they are also used in tunneling. When driving tunnels and destroying coal seams, the most suitable conditions for a combine are considered to be rock hardness up to 75 MPa.
Under such conditions, the harvester shows the highest results in cutting, loading and transporting rocks. The tunneling machine has an excellent layout that provides a low center of gravity, a convenient control system, and it works reliably in uplift.
Chinese tunneling machines
In Ukraine, the Donetsk company DTEK and the Chinese SANY Heavy Equipment Co, Ltd (China) signed a memorandum in which they expressed mutual understanding and intentions to supply Ukraine with the latest mining equipment and coal mining technologies. The signed document also determined the priority areas of cooperation, which will consist in the supply of equipment and technologies, the procedure for providing warranty and maintenance services was agreed. By 2014, it is planned to purchase clearing equipment and several dozen units of tunneling machines.
At a press conference, a representative of SANY Heavy Equipment emphasized that several Chinese tunneling machines are already working at the mines of the Donbass company, and they show good results in the conditions of Donbass.
Speaking at the same press conference on behalf of DTEK's directorate, Andrey Smirnov explained that along with the purchase of domestic equipment, given the significant increase in coal production, DTEK's directorate decided to purchase Chinese tunneling machines. A. Smirnov explained this decision by the fact that the equipment planned for purchase is distinguished by reliability, safety and a fairly high degree of computerization, which is not the case for domestic combines. The resource declared by the Chinese manufacturer for its equipment is 30-50% higher than that of domestic harvesters, and the warranty period is 20 months, which shows how confident Chinese manufacturers are in the quality of their machines.
Roadheader JOY
Beginning in 2005, SUEK's mines began to receive new JOY tunneling machines from Great Britain. This combine model was designed specifically for work in the Kuzbass mines.
The combine is equipped with semi-automatic drilling rigs of the HFX type, which made it possible to abandon the primitive method of drilling with manual rigs and thereby increase the level of work safety. Since 2008, dust extraction systems have appeared on new combines, which created more comfortable conditions for combine operators.
The JOY tunneling machine allows the company to increase the pace of work in mine workings by three to four times compared to the average per team. In the future, equipment of this class will make it possible to increase the level of preparation of the clearing front - up to 1,000 meters per brigade per month.
This modification of the SEU system was developed for tunneling machines of selective action of the KP series, manufactured by Kopeysk Machine-Building Plant JSC.
The SES M2D system is the result of invested efforts and vast experience in operating systems of previous generations.
At the moment, the system is serially equipped at the plant of JSC "KMZ"
- Roadheader KP21-14
- Roadheader KP150
- Roadheader KP220
The complete set of control equipment includes all the necessary subsystems, control units, control panels and actuators to provide control of power electrohydraulics, power supply and protection of various components and elements of the mining machine.
Significant emphasis during development was placed not only on the safety of the machine, but also on the safety of the operating personnel and ensuring comfortable operation.
As a result, the efficiency of tunneling operations increases, including due to equipment downtime during unscheduled repairs.
The electro-hydraulic control system of the SEU "M2D" provides the following functions, which will be described in more detail below.
- Harvester radio remote control
- Combine harvester control from the control panel located at the driver's workplace
- Diagnostics of the presence of malfunctions in individual elements of the system
- Microprocessor protection and control of combine motors
- A set of sensors to control a wide range of parameters of the combine
- System for data transmission to the surface, visualization and generation of analytical reports at the workplace of the mining dispatcher and computers of the management staff
- Pre-start warning and emergency sound signaling
- And others
1. Control panel PU2 SEU2.10.00.000-01
The control panel PU2 is a microcontroller with a 7-inch full-graphic display, a reliable keyboard with opto-isolated contact and non-volatile memory. PU2 is installed in a specialized cassette, which reliably protects it from mechanical damage, simplifies and increases the reliability of installation.
PU2 in the system of SEU "M2RD" performs the following functions:
- control of separate executive devices of the combine from the driver's workplace;
- displaying the parameters of the system and displaying operational information on the display;
- control and transmission of information about the state of the EMS system;
- diagnosing the presence of faults in individual elements of the system;
- event log entry, incl. in black box mode
2. A set of equipment for remote radio control of the KADRUK combine
Equipment "KADRUK" provides remote radio control of the harvester in the line of sight. The body of the Radio Remote Control RPDU AUK75D.70.200.000 is made of durable fiberglass. The combination of joysticks and a push-button keyboard provide convenient and intuitive control of the combines' actuators.
The RPDU battery is charged directly in the mine without lifting “to the surface” when the RPDU is connected by a cable jumper to PU2. At the same time, the RPDU continues to function as a wired remote control.
Also, to improve the safety of mining operations, the RPDU is equipped with an automatic general emergency “stop” function in case of a fall.
3. Set of equipment for installation in the Control Station
The kit includes auxiliary equipment of the system, which performs switching of individual functional units and their control, collection of information from various sensors, power control of electrohydro valves, power supply to the system, as well as MP1 drive monitors.
MP1 drive monitor
MP1 drive monitor is a microprocessor-based device for control, monitoring and protection of the electric motor. MP1 is equipped with a non-contact current sensor and is connected to the central microcontroller (Control panel PU2) via the CAN digital interface. The MP1 drive monitor has the ability to monitor the health of the vacuum contactor control unit circuit by switching the “afterburner” current modes to the “holding” current, which is necessary for vacuum contactors with electromechanical mode control.
Key features of MP1 drive monitor:
- control of the technological overload current of the electric motor with the formation of a "reverse-current-time" protective characteristic (settings for t.overload, t.overload are set from the system menu, stored in the non-volatile memory of the control panel PU2);
- shutdown of the electric motor in case of technological overload;
- saving in the "Black Box" in real time information about the motor currents reaching the values of the overload settings and the values of the overload currents during the period of the protective characteristic;
- control of the overturning current (or “jamming”) of the electric motor with the formation of a protective characteristic and turning off the electric motor in the event of a “turnover” or “jamming”;
- control of the starting current with the preservation of the "profile of the starting current" in the memory. Determination of the completed start for various conditions of starting the electric motor and switching off the electric motor before the "failed" start;
- control of the short circuit current at the outgoing connection (in the load) with the electric motor switched off in the event of a "short circuit";
- control of 3-phase voltage (660/1140V) in the load, control of phase imbalance in the load. In the event of an "inadmissible phase imbalance" - alarm and shutdown of the electric motor;
- monitoring the status of temperature sensors (thermal relays or posistors) built into the stator windings and (or) bearing assemblies of electric motors, with automatic control of the closed state of the line to the temperature sensor and turning off the electric motor in case of overheating of the winding and bearings;
- measuring the insulation resistance of the outgoing connection to the contactor (power cable and stator winding) before switching on the load (motor) with the measured insulation resistance value stored in the module memory (30 kΩ ... 5 MΩ) for automatic comparison with the value “from start to start” (prediction of resistance changes isolation for PPR);
- protection against "frequent starts" in accordance with the restrictions imposed in the specifications for electric motors;
- automatic calculation of the active power of the drive electric motor, taking into account the calculation and storage of energy consumption kWh (data transfer to the main control panel PU2 of the electro-hydraulic control system of the SEU). Accounting for the operating time of the drive (“motor hours”, the number of start-up cycles, including those with maximum load) with fixing these parameters in the non-volatile memory of the MP and the SEU system;
- control of vacuum contactor serviceability with automatic checking of time intervals of switching on (including in the “forcing” mode) and switching off according to the actual working out of the auxiliary contacts and according to the signals of the current sensors (in all three phases);
- detection of attempts to block the vacuum contactor "mechanically" with the preservation of this event in the ECS system;
- detection of malfunctions of vacuum contactor control units responsible for switching from the "Forsage" mode to the "Hold" mode by measuring the currents of the forced mode and the hold mode (relevant for vacuum contactors that have mode control by auxiliary contact, the so-called "electromechanical circuit switching").
4. Harvester electrohydraulic control kit
Designed for electro-hydraulic control of the power hydraulics of tunneling machine mechanisms: the executive body (moving, telescoping), feeder, running machine, conveyor, supports, support hoist, loading.
In the SEU “M2D” System, the EGR SEU.14.00.000 Electrohydraulic Distributor is used as a control electro-hydraulic valve, which is a control electro-hydraulic block for 2 commands. The SEU "M2D" serially supplied to roadheaders KP21-02, KP21-04, KP21-150, KP220 includes a set of 14 electrohydraulic distributors.
The EGR is controlled remotely using the Control Panel PU2 or other control device, incl. according to a given program and algorithm in automatic mode, or in manual mode, using the lever for moving the electromagnet spool.
5. Equipment for monitoring automatic transmission parameters and radio monitoring equipment
It is a set of digital sensors for collecting data on the state of roadheader elements:
- pressure monitoring in hydraulic lines;
- monitoring the position of the executive body;
- temperature monitoring of gearboxes, oil and other elements;
- oil level monitoring in gearboxes and in the oil tank;
- monitoring the concentration of methane and other gases;
- other.
The system can use both "classic" wired sensors and radio monitoring equipment, which is a set of wireless sensors that transmit measurement results via a radio channel to a readout device installed on the combine (radio modem - Stationary Radio Frequency Unit URChS-JN).
Advantages of radio monitoring equipment:
- Ability to transmit data over a radio channel at a distance of up to 30m;
- No external power supply, battery backup;
- The absence of cables and connectors, which allows you to place equipment components in hard-to-reach places, protects against a break in the communication line and increases noise immunity;
- Full diagnostic control, which excludes "sensor imitation";
- High resistance to overloads, dynamic pressure drops and vibrations due to the design features of the sensors;
- Significant simplification of installation due to the absence of cable jumpers;
DDR1 radio pressure sensor
All radio sensors have built-in battery power. Battery life: 9 months.
One radio modem (Unit radio frequency stationary URChS-JN) collects data from 16 radio sensors. Data transfer from the radio modem to the controller (Control panel PU2) is carried out via the digital interface MODBUS (RS485).