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Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022

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A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "H: Geo-Energy".

Deadline for manuscript submissions: closed (11 August 2022) | Viewed by 20240

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Prof. Dr. Piotr Cheluszka

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Department of Mining Mechanization and Robotisation, Faculty of Mining, Safety Engineering and Industrial Automation, Silesian University of Technology, 44-100 Gliwice, Poland
Interests: mining; mining machines; coal mining; tunneling; robotization of mining; use of CAD/CAM in the manufacturing of mining machines

Dr. Eryk Remiorz

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Guest Editor

Department of Mining Mechanization and Robotisation, Faculty of Mining, Safety Engineering and Industrial Automation, Silesian University of Technology, 44-100 Gliwice, Poland
Interests: theoretical and experimental research of mining machines; tests of longwall machines equipped with chain haulage systems; developing software for simulating dynamic phenomena occurring in mining machines; application of optimization methods to shape the dynamic characteristics of mining machines in the direction of reducing the value of dynamic loads and reducing power consumption

Special Issue Information

Dear Colleagues,

Mining as a branch of industry cannot do without modern, highly efficient, energy-saving, and reliable machines. The mining industry creates a wide range of technologies and mining machines designed for their implementation. Mechanization systems used in mining works are adapted to the place and method of mining (opencast, underground, or borehole mining), the specificity of the deposit, and the manner of its deposition. However, mining is not only associated with extraction of raw materials. Mining techniques are also used to make a number of construction objects, such as road and railway tunnels, garages, hydro-technical galleries, etc.

The development of mining machinery is driven by the aims of ensuring a high mineral resource extraction efficiency, a high speed of tunnel drilling, minimizing the costs of mining works, and increasing work safety. This development is largely the result of intensive research work carried out in various R&D centers, universities, and institutes around the world, dealing with model, simulation, and experimental research of mining machines.

Mining machines are dynamic objects. They are subject to strong vibrations and dynamic loads during the execution of the working process and in interaction with the environment. Ensuring the expected durability and reliability of mining machines requires knowledge of the dynamic phenomena accompanying their operation. The minimization of dynamic loads is the basis for the optimal design of mining machines.

This Special Issue, titled “Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines”, will focus on matters connected with the technological development of mining machines used in underground and surface mining, tunneling, and civil engineering. I invite you to submit original scientific papers presenting results of theoretical, simulation, and experimental research on mining machines and the working processes they carry out, especially for:

The mechanical mining of rocks;
Rock crushing;
Spoil haulage;
Mine transport;
Drilling machines;
Roof support for mining excavations; and
Mineral processing,

in terms of improving their dynamic condition and minimizing the energy consumption of their work process.

This Special Issue aims to publish innovative research results, including those of an applied nature. Papers presenting the results of research into the automation of mining machines to ensure a high degree of use of their technical potential, minimizing energy consumption and their dynamic load, and improving work safety are also welcome.

Prof. Piotr Cheluszka
Dr. Eryk Remiorz
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Energies is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

mining machines
energy consumption
dynamic loads
optimization
modeling
simulation investigations
experimental investigations
automation
reliability
durability

Published Papers (10 papers)

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Research

25 pages, 15279 KiB

Open AccessFeature PaperArticle

The Use of a Roadheader Simulator in Research of Dynamics and Energy-Consumption of Excavating Underground Roadways and Tunnels

by Piotr Cheluszka, Eryk Remiorz and Jamal Rostami

Energies 2022, 15(18), 6673; https://0-doi-org.brum.beds.ac.uk/10.3390/en15186673 - 13 Sep 2022

Cited by 2 | Viewed by 1803

Abstract

Boom-type roadheaders are commonly used for excavation of roadways in underground mines, tunnels, and other architectural structures using trenchless techniques, as well as sinking shafts and occasionally excavating the harder soil and softer formations in cut and cover construction. The main research and development of these machines is to offer solutions for automatic control. This refers to automation or robotization of the operation, and raises the possibility of their eventual unmanned operation. This article presents a roadheader research simulator which implements experimentally verified mathematical models describing the dynamics of a roadheader in operation and the rock cutting process. Due to very high computational requirements, a distributed system comprising several workstations connected via TCP/IP was used. Both the visualization of the roadheader in the heading face of the excavation and the graphic simulation of the course of the rock-cutting process were carried out using the Autodesk Inventor Professional 2022 graphics engine. It provided the simulator with a virtual scene environment and enabled the control of the roadheader model’s movement during the simulated cutting process, including the generation of breakout graphics in the heading face while drilling a roadway or tunnel. The presented roadheader simulator enables the determination of various time characteristics, for example, dynamic loads, power demand, efficiency, energy consumption, and others. It is still under development. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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24 pages, 11175 KiB

Open AccessArticle

Identification of a Mathematical Model for the Transformation of Images for Stereo Correspondence Measurements of Mining Equipment

by Piotr Cheluszka and Amadeus Jagieła-Zając

Energies 2022, 15(17), 6339; https://0-doi-org.brum.beds.ac.uk/10.3390/en15176339 - 30 Aug 2022

Viewed by 949

Abstract

The stereometry of the working units of mining machines is optimized at the design stage, in terms of selected criteria based on computer simulations of the mining process. The recovered bodies of cutting heads or drums used in manufacturing are regenerated in the overhaul process. Ensuring that their dimensions comply with the nominal ones is labor-intensive and raises production costs. However, deviations of these components from the nominal shape can make it difficult to position the pick holders (which can cause collisions) or make welding them impossible (which results from too large a distance between the pick holders’ base and the side surface of the working unit). This applies especially to robotic technologies. By utilizing automatic (online) measurements of the distribution of the actual distances of the pick holders’ bases from the side surface of the working unit (taken during their positioning using a robot), it is possible to correct their positions without changing the setting of the pick itself. This measurement can be carried out using the non-contact stereovision method. This paper presents a method of matching raster images obtained from a stereovision system installed on an experimental robotic station. The results are presented of the numerical research carried out to select a mathematical model of the geometric transformation of images, for ensuring the effectiveness of the developed method. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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17 pages, 16424 KiB

Open AccessFeature PaperArticle

Conveyor Intermediate TT Drive with Power Transmission at the Return Belt

by Piotr Bortnowski, Adam Gładysiewicz, Lech Gładysiewicz, Robert Król and Maksymilian Ozdoba

Energies 2022, 15(16), 6062; https://0-doi-org.brum.beds.ac.uk/10.3390/en15166062 - 21 Aug 2022

Cited by 2 | Viewed by 1475

Abstract

Intermediate linear booster drive can solve many problems of transport by long route conveyors. At the same time, operating costs are significantly reduced. There are solutions using intermediate belt drives, usually involving friction coupling in the carry belt. From a theoretical point of view, it is possible to transmit the friction force on an additional section in the return belt. The article presents a theoretical and experimental analysis of this solution and a comparison with a drive operating in a conventional solution. The transferred forces, the variability of the belt tension as well as the efficiency and stability of the drive for both solutions were compared. The use of additional coupling in the return belt makes it possible to increase the transmitted friction force and achieve a better rate of electricity consumption. The solution can be useful in currently existing intermediate drives, where it is possible to support the return side and transmit power. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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21 pages, 9688 KiB

Open AccessArticle

Advancement of the Monitoring System for Arch Support Geometry and Loads

by Mariusz Woszczyński, Joanna Rogala-Rojek and Krzysztof Stankiewicz

Energies 2022, 15(6), 2222; https://0-doi-org.brum.beds.ac.uk/10.3390/en15062222 - 18 Mar 2022

Cited by 2 | Viewed by 1156

Abstract

As part of the RFCS project, which aimed to improve transport safety in mines, ITG KOMAG proposed a system for monitoring loads and geometric of arch support. The system’s function is to control safety, mainly during suspended monorail runs. This paper presents a hardware model and a measurement method based on the use of vibrating wire strain gauges and draw-wire sensors. The challenge was to properly adapt the vibrating wire strain gauge operation to the requirements of the ATEX directive on the safe use of electrical equipment in underground mines. The signal transducer algorithm and potential mounting locations for the proposed sensors were discussed. The results of tests carried out using the ŁP arc support are presented, reflecting the actual behavior of the casing during loading in accordance with the test methodology proposed by the Central Mining Institute. In order to compare the results with another measurement method, film strain gauges were additionally applied. The results confirm the usefulness of the proposed method for testing in real conditions. The speed and simplicity of installation of vibrating wire strain gauges provides an advantage over the use of film strain gauges, which are very difficult to install in underground conditions. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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16 pages, 5242 KiB

Open AccessArticle

Energy Key Performance Indicators for Mobile Machinery

by Pedro Roquet, Gustavo Raush, Luis Javier Berne, Pedro-Javier Gamez-Montero and Esteban Codina

Energies 2022, 15(4), 1364; https://0-doi-org.brum.beds.ac.uk/10.3390/en15041364 - 14 Feb 2022

Cited by 2 | Viewed by 1320

Abstract

Mobile machinery manufacturers must face and deal with reducing fuel consumption, rising prices, and environmental pollution. The development of methods to evaluate the efficiency and effectiveness of the energy performance of hydraulically actuated systems has become a priority for researchers and OEMs, Original Equipment Manufacturers. In this paper, a new methodology that is based on Key Performance Indicators, KPI, is proposed with different goals: (i) to evaluate the energy performance and the monitoring of its evolution in the different stages of its life cycle (design, commissioning, optimization, retrofit, etc.); (ii) compare the energy levels between machines of different sizes and different brands in a benchmarking process; and (iii) establish a database that is state of the art, which facilitates setting achievable goals or limits for improvement. These KPI values can be deduced simply from the energy balances that were made from the experimental study of various machines over a relatively long period. This methodology has been applied to typical hydraulic systems for lifting and lowering loads that are used in a wide variety of mobile machines of different mechanical designs and sizes. Still, it can be included in the generic name of “loaders”. A KPI’s values for the three machines are presented in a dashboard as a decision-making tool. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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16 pages, 14759 KiB

Open AccessArticle

A Mobile Robot-Based System for Automatic Inspection of Belt Conveyors in Mining Industry

by Jarosław Szrek, Janusz Jakubiak and Radoslaw Zimroz

Energies 2022, 15(1), 327; https://0-doi-org.brum.beds.ac.uk/10.3390/en15010327 - 04 Jan 2022

Cited by 24 | Viewed by 3853

Abstract

Mechanical systems (as belt conveyors) used in the mining industry, especially in deep underground mines, must be supervised on a regular basis. Unfortunately, they require high power and are spatially distributed over a large area. Till now, some elements of the conveyor (drive units) have been monitored 24 h/day using SCADA systems. The rest of the conveyor is inspected by maintenance staff. To minimize the presence of humans in harsh environments, we propose a mobile inspection platform based on autonomous UGV. It is equipped with various sensors, and in practice it is capable of collecting almost the same information as maintenance inspectors (RGB image, sound, gas sensor, etc.). Till now such experiments have been performed in the lab or in the mine, but the robot was controlled by the operator. In such a scenario the robot is able to record data, process them and detect, for example, an overheated idler. In this paper we will introduce the general concept of an automatic robot-based inspection for underground mining applications. A framework of how to deploy the inspection robot for automatic inspection (3D model of the tunnel, path planing, etc.) are defined and some first results from automatic inspection tested in lab conditions are presented. Differences between the planned and actual path are evaluated. We also point out some challenges for further research. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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29 pages, 8109 KiB

Open AccessArticle

Methodology for Assessing the Stability of Drilling Rigs Based on Analytical Tests

by Łukasz Bołoz and Artur Kozłowski

Energies 2021, 14(24), 8588; https://0-doi-org.brum.beds.ac.uk/10.3390/en14248588 - 20 Dec 2021

Cited by 6 | Viewed by 1989

Abstract

Underground mining machines, such as wheel-tyre drilling rigs, are articulated and equipped with booms that project far beyond the undercarriage. Such a structure makes these machines prone to losing stability. Hence, it is necessary to analyse the distribution of masses and geometry as well as their broadly understood stability during the entire design process, taking into account many factors resulting from the manner and conditions of their operation. However, there are no appropriate computational models that would enable analytical tests to be carried out for machines with this kind of construction. This article is concerned with the author’s computational model, which allows the stability of single- and twin-boom drilling rigs to be quickly assessed. The model makes it possible to perform analyses without having to solve differential equations that are present in dynamic models or using specialist software based on CAD and CAE tools. The developed model allows determination of the pressure of wheels and jacks as a function of many important parameters and variables. Additionally, the distances of the centre of gravity from the tipping edge are calculated. The developed computational model was verified by comparing the obtained results with the results of the full dynamic model, the results of model tests carried out in the CAD/CAE program, and the results of empirical tests of wheel and jack pressures on the ground for the selected drilling rig. The model was subjected to verification and validation, which proved that it was fully correct and useful. The model was used to prepare a practical and user-friendly calculation sheet. Apart from the numerical values, the calculation sheet contains a graphical representation of the machine, the location of the centre of gravity, the tipping edges, as well as graphs of the wheel and jack pressures. Next, analytical tests of the stability of the selected drilling rig were carried out. The obtained calculation results are consistent with the results of empirical research. The computational model and the spreadsheet provide handy tools used during the design process by one of the Polish company’s producing drilling rigs. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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16 pages, 8730 KiB

Open AccessArticle

Research on the New Drive of a Laboratory Screen with Rectilinear Vibrations in Transient States

by Jacek Feliks, Paweł Tomach, Dariusz Foszcz, Tomasz Gawenda and Tomasz Olejnik

Energies 2021, 14(24), 8444; https://0-doi-org.brum.beds.ac.uk/10.3390/en14248444 - 14 Dec 2021

Cited by 3 | Viewed by 1905

Abstract

The paper presents the results of research on the vibrating motion of a laboratory screen with a rectilinear (segmental) trajectory of vibrations during its start-up and braking. The investigations were carried out on a modernized stand equipped with a system of two vibrating motors applied in newer solutions of industrial screens, which are mounted directly on the riddle. The tests were carried out for three different frequencies using three-axis acceleration sensors. The analysed parameter was the increase in the amplitude of vibrations in transient states compared to the amplitude during the stable operation of the device. The maximum multiplication of the vibration amplitude of the classic drive system during start-up was 9.7 (mm/mm) in the vertical direction and 5.7 (mm/mm) for the new system. During braking, the maximum multiplication of the vibration amplitude of the classic drive system was 6.9 (mm/mm) vertically, while for the drive system with vibration motors, it was 11.4 (mm/mm). The absence of flexible couplings in the drive system reduces the damping of vibrations and increases the value of amplitude during the start-up and free braking of the machine. This does not have a major influence on the correct operation of the machine in a steady state. However, the use of the new drive system resulted in a significant reduction in power demand and shortened the start-up time, which has a positive effect on the operating costs of the machine. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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29 pages, 8828 KiB

Open AccessArticle

Numerical Studies of the Dynamics of the Roadheader Equipped with an Automatic Control System during Cutting of Rocks with Different Mechanical Properties

by Piotr Cheluszka

Energies 2021, 14(21), 7353; https://0-doi-org.brum.beds.ac.uk/10.3390/en14217353 - 04 Nov 2021

Cited by 5 | Viewed by 1792

Abstract

The process of cutting rocks with a boom-type roadheader results in extreme dynamic loads and vibrations. Mining, especially in the case of hard rocks, is associated with large energy consumption, which, when combined with low process efficiency, can lead to low drilling performance. These phenomena are undesirable because excessive dynamic load leads to low machine durability, as well as deterioration of work conditions and safety. Low mining efficiency affects the economics of mining works conducted using roadheaders. However, these adverse effects can be minimized by optimizing the cutting process, thanks to the automatic control of the roadheader. The present article discusses the concept of automatic control of a boom-type roadheader’s cutting heads movement. Based on previously conducted computer investigations, it was assumed that reducing the energy consumption of the cutting process and improving the dynamic state of the roadheader (objective functions) are possible only by controlling three of the four parameters characterizing the cutting process: angular speed of the cutting heads, boom swinging speed, and cut height. The web of cut and workability of the rock can be treated as variables of a stochastic nature. This paper presents selected results of computer tests during simulated cutting of rocks with different uniaxial compressive strengths (UCS) in automatic and manual mode. In addition, the tests studied the behavior of the roadheader during the cutting of rocks with variable workability, which is typical of drilling excavations in a layered rock mass. The results of simulated cutting in automatic and manual mode were compared to assess the effectiveness of the adopted automatic control strategy. It was found that the algorithm developed for automatic control of the cutting heads’ movement allows reducing the consumption of cutting energy by up to half compared to the consumption during cutting in manual mode. Furthermore, it was found to improve the dynamic state of the machine. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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17 pages, 6033 KiB

Open AccessArticle

Determination of the Bucket Wheel Drive Power by Computer Modeling Based on Specific Energy Consumption and Cutting Geometry

by Ildiko Brînaș, Andrei Andraș, Sorin Mihai Radu, Florin Dumitru Popescu, Iosif Andraș, Bogdan Ioan Marc and Alexandru Robert Cioclu

Energies 2021, 14(13), 3892; https://0-doi-org.brum.beds.ac.uk/10.3390/en14133892 - 28 Jun 2021

Cited by 10 | Viewed by 2554

Abstract

Starting from the general principles of material cutting, with applicability to coal and overburden excavation using bucket wheel excavators (BWEs), this paper proposes another method for calculating the drive power of the bucket wheel excavator by computer modeling. This approach required two steps. In the first step, the volume of the excavated material for one slewing movement of the boom and for a particular excavation geometry was determined, and the slewing time in the open pit coal mine was measured. In the second one, the values of the specific energy (SE) consumption for cutting were determined by laboratory tests on samples of material taken from the open pit mine. The proposed method allows for the estimation of the load of the bucket wheel drive motor by taking into account only the specific energy necessary for the cutting of the material, the excavated volume during one slewing, and the time required to excavate this volume, and not the wear coefficients of the teeth or bucket edge. This method is important for establishing the correlation between the height of the excavated slice and the slewing speed of the boom in order to optimize the drive power of the bucket wheel and thus improve energy efficiency, increase the performance of excavators, and reduce operating costs. Full article

(This article belongs to the Special Issue Optimization and Improvement of Energy Consumption and Dynamic Loads of Mining Machines 2022)

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