JAN-FEB 2018

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 27 2018 • VDMA MINING SUPPLEMENT 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 controllers 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 ex- actly 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." Voith recently installed a TurboBelt DriveControl system at SsangYong Cement's Donghae plant in South Korea. By implementing the Voith system, the quarry managed to overcome local material han- dling challenges to increase its production of limestone significantly. SsangYong had used Voith's equipment for more than 20 years and consulted the company for this retrofit project. With a goal of dou- bling the tonnage from the main quarry to the cement plant, essential technical changes became necessary. The conveying route was cov- ered by two belt conveyors with the longer one, a 12.8-km one-flight conveyor, belonging to the five longest single conveyors worldwide. After an initial analysis of the conveyor system, the belt speed was doubled from 3 meters per second (m/s) to 6 m/s to increase the con- veying tonnage. To allow for that increase, the gear ratio not only had to be changed, but also the installed drive power. The most cost-ef- fective solution was to install new drivetrains along the long conveyor (SB500). The installed power is now 2 x 1.2 megawatts (MW) at the head and 1 x 1.2 MW at the tail of the conveyor. The existing Voith drives for the SB500 were used to double the number of drivetrains on the shorter 2-km SB200 conveyor. After 20 years, the drives only needed routine maintenance checks in order to connect with the new controller. The new configuration of the SB200 drive system consists of 4- x 600-kW installed power at the head equipped with new gearboxes. In addition to the new drivetrains, the overall performance of the drives was improved. Before the retrofit, the startup procedure of the long conveyor with 12.8 km took more than 10 minutes. The difficul- ties with control technology and conveyor dynamics in the past were resolved with the Voith TurboBelt Drive Control. The conveyor now starts up fully loaded with about 2,100 tons of aggregate, within half of the previous startup time, and the torque transmission con- trol achieves an extremely smooth and steady acceleration. 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. Voith recently installed a TurboBelt DriveControl system at SsangYong Donghae plant in South Korea. ABB has a new gearless solution for medium-powered conveyor drives.

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