JAN-FEB 2018

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 28 VDMA MINING SUPPLEMENT • 2018 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 implementing 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 paral- lel 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 sys- tems. These systems in Europe are often characterized by the combi- nation 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 con- tent, and influenced by non-ideal coal seam courses. To secure an efficient combustion process, it is necessary 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 online 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. Condition Monitoring Bosch Rexroth was working with connectivity long before concepts like Industry 4.0 became popular. The company's first pilot solution was installed around 15 years ago by a large iron ore miner. At that time, operating data was relayed to the Hägglunds team over the GSM network, not more than a couple of times per day. "Back then we simply called it remote monitoring," said Uno Sundelin, manager, mining and materials handling for Hägglunds Products. "The equipment recorded important indicator values, and thresholds were set for pressure, temperature and so on. By having good routines for monitoring those values, we could prevent damage from happening if something outside the set parameters occurred with the drive. It was basic, but it worked and was well appreciated by the customer. It established the principle." Bosch Rexroth's solution today, known as Hägglunds Condition Monitoring premium, CMp, is a quantum leap from that first system, with more sensors, real-time reporting and an analytic algorithm that has far greater diagnostic power. It can be found in Hägglunds' drive systems worldwide, including at that first iron ore mine, where it safeguards, for example, the availability of a large belt conveyor. "Belt conveyors are typical positions where you want to have condition monitoring," Sundelin said. "If a conveyor stops, the whole production often stops. They're autonomous systems, and if you have no parallel path, you want to see in good time if something is outside the norm, so that you can take any actions needed to keep the conveyor running." The Hägglunds CMp system provides advanced notice with the help of ODiN, Bosch Rexroth's proprietary analysis solution. Using readings from sensors installed throughout the drive system, ODiN creates a machine health index that provides an accurate picture of the system's condition. It is the health index — not the individual sensor signals — that makes the difference for mining customers. The usefulness of the data collected through Hägglunds CMp becomes apparent when Bosch Rexroth experts interpret it and determine what service ac- tions might be needed to keep the system running. "Anyone can deliver sensor data, but data says nothing to the miners," said Mattias Ljungdahl, application manager, Hägglunds Inside Intelligence. "With ODiN we have a constantly learning al- gorithm that takes the sensor data and compares how things look normally with how they look right now. When our experts see a di- vergence from that health index, they determine what is happening and what needs to be done. It's that combination of health index and expert analysis that makes our solution work for the customer." A further difference, according to Wolfram Ulrich, vice president sales and service, Hägglunds Products, is the integration of Häg- glunds CMp with Bosch Rexroth's total service offering. What cus- tomers buy, he said, is not just knowledge, but also the ability to act. "The connectivity Bosch Rexroth offers is paired with fast, pro- fessional reaction by technicians with deep knowledge," Ulrich said. "Monitoring is everywhere today, but our ability to interpret, conclude and take corrective actions is one of a kind." "Simply delivering a high-performance mining machine is not enough for today's global customers," Ulrich said. "Suppliers need to know how their customers want to operate their machines, and how to secure the information that will let them do it most effective- ly. What Bosch Rexroth offers through drive connectivity in its full extent is a proven way for OEMs to take the next step for optimized designed machines and the end users to minimize maintenance costs, optimizing the availability plus running the processes as ef- ficient as truly possible." Bosch Rexroth's Hägglunds drive provides the power to clear the truck dump.

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