VDMA

INDIA 2018

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 31 2018 • VDMA MINING SUPPLEMENT ancing, the system understands a conveyor's starting behavior," Fleuchaus said. "The system knows why the conveyor was shut down and the operating conditions when it was shut down. Startup would be influenced by the load and, if it's a multimotor arrangement, the motors and drives might require a staggered start and the control system would decide which motor would start first." The TurboBelt 500 TPXL, which has been developed especially for new belt conveyors, is a smarter solution and has a smaller footprint for the same level of power transmission. It operates at a higher efficiency and has a simple method for controlling the fluid inside the coupling. "By changing the fluid level of the fill control coupling, we alter the starting behavior of the coupling," Fleuchaus said. "If you have an emergency stop with a belt that is potentially 10% to 15% overloaded, you have to ensure safe restarts." As far as logic, two lines run between TurboBelt DriveControl to the main PLC. In the past, an open source architecture was designed by PLC manufacturers, that may not have understood the principles of fluid couplings. "The function of the coupling and its behavior is a topic of its own," Fleuchaus explained. "So we created our own controller based on the features necessary to start and operate the system for reliable operation," Fleuchaus said. "With PID control- lers and sensors, we can focus on the coupling's behavior as far as torque and speed. We can calculate the power absorbed from the motor based on coupling slip. "We focus on the driven side of the conveyor and analyze the torque transmitted to the belt at what speed," Fleuchaus said. "We know exactly when the system was stopped and the last level of motor power consumption. Now, we can perform an optimized restart because our controller has saved the last value, which forms the basis of the restart conditions. It knows the difference between an emergency or overloaded shutdown and it automatically selects the proper restart scenario." Providing the Power ABB, as well as the VDMA, has a long history in the mining industry. Located in a traditional German mining area, with the Center of Excel- lence in Cottbus, ABB has decades of expertise in electrification and automation for open-pit mining and bulk material handling applica- tions along the entire mining chain from pit to port. The many years of experience was always coupled with innovative solutions that incorpo- rated the newest technology trends, such as digital mining solutions based on ABB Ability, its open industrial internet technology platform. ABB also has long-term successful partnerships with worldwide leading mining equipment suppliers, such as Komatsu for electric rope shovels and TAKRAF Tenova for high-power gearless conveyor drives. ABB Germany has engineered a product platform for low-voltage AC Drives for extreme mining conditions and has made more than 100 de- liveries during the past 12 years. The product life cycle of this successful AC Drive system will now go into classic phase to ensure the availability of spare parts from ABB Drives Service for another 12 years. Reliability and performance convinced Komatsu to deploy the next generation of ABB low-voltage drives, which provide more power in the same footprint. A FEM structure analysis of the cabinet system and IGBT live time analy- sis will ensure the proven quality level for high capacity shovels. Together with TAKRAF Tenova, ABB is partnering in the devel- opment of gearless conveyor solutions. A recent example is the execution of the world largest conveyor system at the Chuquica- matacopper mine in Chile, which will connect the newly developed underground operation directly with the concentrator. While recent projects were mainly driven by gearbox limitations for high-power drives (3.7 MW per motor), ABB recently developed a solution for the medium-power range (1.3 MW per motor) to make this technology economically feasible for a broader range of conveyor systems, including on mobile equipment. A core element is a perma- nent magnet motor specifically designed for mining applications. Working with local mine operator LEAG, ABB is now implement- ing a pilot project of this solution that is showing very encouraging results in operation. The new gearless solution was installed on a high-capacity (15,000 mt/h) discharge conveyor of a bucket-chain excavator in parallel with the existing geared drive. The operational data demonstrate the advantages of the gearless solution with less components like: • Higher reliability (50% lower failure rate) and less maintenance; • Higher efficiency with lower energy consumption (according ISO 50001) and lower noise emission; and • Extended lifecycle (expected motor lifetime of 25 years is 10 years longer than with a traditional gearbox). The new solution can be applied for both greenfield and brown- field systems, and significantly decreases the cost threshold for gearless conveyor technology. After the successful implementation of the stockyard manage- ment system (SYMS) at Vale's iron ore distribution hub in Malaysia, ABB has extended the functional scope for the material tracking and quality management in integrated lignite mine and power plant systems. These systems in Europe are often characterized by the combination of different mines feeding a nearby thermal power generation plant without additional coal processing. The quality of the mined lignite is highly variable in terms of calorific value, ash, sulfur content, and influenced by non-ideal coal seam courses. To secure an efficient combustion process, it is neces- sary to homogenize the coal feed by selective mining and blending processes on stockyards. ABB is now executing an online coal quality management sys- tem project that tracks the quantity and quality of the excavated coal directly on the conveyor lines by the use of belt scales and on- line analyzers. The system compares the parameter from the pro- duction planning system, which is based on the geological model of the coal deposit with the real measured values. It then creates a feedback loop to the production system. The new parameters for the excavating and blending process, which are calculated online, are transmitted directly back to the mine's control system and the stockyard. So the system then enables continuous quality control of the coal feed with an optimal mix of blending directly on the convey- or lines, or if necessary, by the use of stockyard blending in parallel. ABB has a new gearless solution for medium-powered conveyor drives.

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