Bolter Miner ABM25-016

Bolter Miner ABM25-016

Technical Description

Bolter Miner ABM25-016

ABM25 Technical Description

ABM25

ABM25-16 May 2011 Page 1 Copyright © Sandvik Mining & Construction Pty Ltd

TABLE OF CONTENTS

1 TECHNICAL DESCRIPTION 2 1.1 General 2 1.2 Technical data 3 1.3 Dimensions of the machine 6 1.4 Cutter head profile 6

2 MACHINE CONCEPT - MAJOR COMPONENTS 7 2.1 Cutter module 8

2.1.1 Gear box 9 2.2 Slide frame 10 2.3 Loading equipment 11

2.3.1 Gear box 12 2.4 Chain conveyor 13 2.5 Track equipment 14

2.5.1 Track transmission 15 2.6 Frame 16

2.6.1 Rear stabiliser (stab jack) 16 2.7 Electric system 17

2.7.1 Electric Drive 17 2.8 Hydraulic System 18 2.9 Bolting System 19

WARNING

Important information!

Read and understand all safety messages and the contents of this operating manual in its entirety. Manuals explain residual risks related to this machinery Ignoring safety instructions could result in serious injury or death.

Before machine operation, maintenance, repair or transporta-tion, users MUST understand and adhere to the instructions of this manual.


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1 TECHNICAL DESCRIPTION

1.1 General The machine was designed for rapid entry roadway development. It is basically a widehead Continuos Miner incorporating special design features with regards to coal cutting and loading. Bolting rigs are an integrated part of this machine. The layout of the machine al-lows space for 4 roof bolters and 2 rib bolters. All drill rigs as well as the rib bolt-ers are placed immediately behind the cutter-drum. The new design enables a simultaneous cutting- and bolting operation (refer to attached drawing: cutting and bolting sequence). In order to optimize the conditions for operators and face crew the machine is fit-ted with an onboard dust collecting and scrubbing system. The emphasis is an integration of well proven technology into one machine which gives better advance rates. The machine features are as follows:

• Simultaneous cutting and bolting operation. • Low rotation speed of the cutter-drum and high installed power, to reduce

dust development to a minimum. • Onboard rib bolting and roof bolting rigs. • The loading- and conveying unit moves independently from the cutting device

in order to achieve best loading efficiency. • Fully shielded extendable bolting platforms for optimized ergonomics. • Rib protection for bolter operators safety. • Electronic controlled sump- and shear-movement to optimize the cutting se-

quence as well as the work of the cutter motor. • Radio-remote control system for all functions - except drilling operation. • Radio-remote control AS 4240 compliant. • Optional data logging system. • Fully integrated water spraying system. • Low ground pressure of crawler tracks. • No movements of crawler tracks during sumping action (therefore no destruc-

tion of floor in soft conditions). • Fully supported roof for operators safety,due to support-canopy behind the

cutter-drum. • Fully automated greasing system for low service requirements.


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1.2 Technical data

Serial No.: 016 General1

Total weight t approx. 97

Total installed power2 (at 1000 [V], 50 [Hz]) kW 547

Overall length mm approx. 11000

Cutting width in operation mm 5200

Cutting height, max. mm 3500

Cutting height, min. mm 2900

Machine overall tramming height mm 2700

Machine overall tramming width mm 4800

Max. width of crawler tracks mm 2896

Machine ground pressure N/cm² 22

Ground clearance mm 310

Navigable Area of Application Cone radius, min. m approx. 25

Basin radius, min. m approx. 25

Maximum cross grade ability ° / gon ±4 / ±5.6

Slope upgrade / incline without stabilizing ° / gon ±18 / ±20

Loads to be applied Maximum vertical load to the drum [tons] 10

Maximum vertical load to the end of swivel conveyor [tons] 1

Towing at the lugs (machine rear plate LH, RH) [tons] 15 each

Cutting system - widehead drum Miner Shape for profile Rectangular

Drum width mm 5200

Drum extension, hydraulically operated mm 2 x 200

Drum diameter mm 1150

Cutting speed m/sec 1.5

Sumping speed, variable mm/sec 20 – 50

Max. vertical cutting (shearing) force kN 300

Cutter motor, installed power kW see “electrical system”

Sumping aid (longitudinal slide) mm 1000

1 All dimensions and technical data are theoretical figures. The values are within the usual tolerances. 2 Without dust scrubber.


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Bolting system Distance roof support to face mm 2216

Distance drill rig: face (centre) mm 1490

Distance between centre bolts mm 900

No. of bolts / W. strap 2 - 8

Bolt length (single pass) mm 2100 or 2400

Rib bolting left and right

Bolt type Chemical

Drilling Rotating

Support canopy Total force supplied to the roof kN 2 x 200

Loading system Loading device Spinners

Loading capacity t/min 25

Loading width mm 4270 - 5200

Loader motor, installed power kW see “electrical system”

Retraction facilities mm 2 x 465

Conveying system Conveyor width mm 760

Conveyor chain speed m/sec 2.1

Conveyor capacity t/min 25

Conveyor overhang mm 3000

Conveying capacity t/min 25

Conveyor motor, installed power kW see “electrical system”

Tramming Tramming speed, variable [m/min] 3.5 / 7.0 / 17.0

Ground clearance mm 310

Ground pressure N/cm² 22

Track pulling force kN 2 x 400

Track overall width – outside od the tracks mm 2896

Track length on ground mm 3400

Track chain width mm 570


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Dust suppression External sprays for dust supprension. Integrated dust collection and vent duct.

Hydraulic system Hydraulic motor, installed power kW see “electrical

system”

Pressure max. bar 250

Filtration system, back flow filter and pressure filters

Tank capacity l 450

Filler pump kW see “electrical system

Electrical system Electric potential [V] / [Hz] 1000 / 50

Radio remote control standard

Installed power:

Cutter motor kW 270

Hydraulic motor kW 132

Loader motors kW 2 x 36

Conveyor motors kW 2 x 36

Filler pump kW 0,75


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1.3 Dimensions of the machine ALPINE BOLTER MINER ABM253

656.56000.803 A

1.4 Cutter head profile The cutting height is always depending on the bolting height, you can never cut higher than you can install roofbolts.

3 All dimensions and technical data are theoretical figures. The values are within the usual tolerances.


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2 MACHINE CONCEPT - MAJOR COMPONENTS The machine is designed for rapid roadway development in lower seams reach-ing from 2900 mm up to 3500 mm seam high, allowing high advance rates while remaining at face for efficient long-wall development drivage. It is electrically powered. Optimum comfort and safety for operators are provided due to fully shielded cutting area.

1 Cutter boom with E-Motor

2 Cutter drum with gear box

3 Slide frame

4 Apron with drives

5 Frame

6 Chain conveyor

7 Track

8 Stab jacks (rubber bumper)

9 Canopy

10 Rib bolter front/rear

11 Ventilation duct

12 Electric equipment

13 Hydraulic equipment

14 Water supply

15 Roof bolter

16 Multi line lubrication unit

17 Canopy jack

18 Wishbone

6

8 14

16 7

12

15 4 2 1

11 513 3 18 917

10


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2.1 Cutter module The cutter assembly comprises the cutter boom, the cutter motor, the cutter gear and the cutter drum. The cutter boom is a single piece solid steel structure. The gear box is a spur-bevel-planetary drive arrangement. The cutter drum end sections are extendible by 250 mm each side, item 7. Max. penetration (dinting) from the level 1000 mm.

Separating Line

1 2

3 4

5

6

7

7

8

8

9

10

11

11

12

12

1 Cutter boom

2 Gear box

3 Bearing, cutter boom

4 Lifting cylinder, cutter boom

5 Motor cover, E-Motor 270 kW

6 Cutter drum, central part

7 Drum extension, right/left

8 Cutter drum, lateral part

9 Bolt connection, central part

10 Bearing, lifting cylinder

11 P.t.o. lateral part, right/left



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2.1.1 Gear box The gear consists of two spur wheel steps, one bevel gear step with intermediate wheels and two planet gear step on each drive side.

Technical data Power kW 270

Motor speed, 50 [Hz] [rpm] 1480

Input torque Nm 1750

Gear transmission ratio i 57.6

Driven shaft speed [rpm] 25

Output torque [kNm] 100

Gear oil quantity l 110

Weight kg 9800

All mating surfaces are sealed by suitable sealing compounds (Loctite) against oil penetration. The driving shaft bearing is provided with shaft gaskets, the driven shaft bearing is sealed with rotating mechanical seal.


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2.2 Slide frame (Sumping frame) The horizontal slide frame allows sumping of the cutting unit together with the conveyor, independent from the main frame thus enabling simultaneous cutting and bolting.

Fitted with Brass bushes to slide on the sumping guides bolted to the main frame. The sumping frame carries:

• Cutter boom base and the vertical shear cylinders.

• Chain conveyor which is connected with the load-ing apron. The sliding support for the conveyor allows the movement of only 0.55 m for the loading apron and the chain con-veyor.

The sumping frame is moved via the sumping cylinder, con-nected to the sumping frame and the main frame. Also mounted on the sumping frame is the boom level syn-chro, it informs the micro processor any time of the ex-act position of the cutter boom.

1 Slide frame


3 Bearing, sump cylinder

4 Bearing, lifting cylinder

5 Sliding stone, conveyor

6 Slide bearing for guide rods

7 Ledge of grease points

8 Guide rods

9 Position sensor for cutter boom

7

6 6

5 1

3

8

2 9 4


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2.3 Loading equipment The loading assembly comprises the loader apron, two loader-conveyor trans-missions and two spinners for gathering the material. The loading assembly moves forward when the cutter drum is sumped in, this guarantees best loading efficiency. The gathering-conveyor system is driven by two electric motors (36 kW each) via bevel-spur gear transmissions.

1 Loader apron

2 Loading stars (spinners)

3 Extension left

4 Extension right

5 Gear box

6 E-Motor, 2 x 36 kW

7 Roller

8 Lifting clyinder

9 Extension cylinder

1

3

4

7

2

5 6

8 9


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2.3.1 Gear box The loading drive is a combination of a spur gear and a bevel gear. Each gear-side is driven by one electric motor. The electric motor of the right gear side must turn counter-clockwise, that of the left gear side must turn clockwise.

Technical data Nominal power kW 36

Revolution [rpm] 1440

Nominal input torque Nm 239

Output speed U/min 48,5

Nominal output torque 7088

Output torque, max. Nm 50000

Ratio, i 29,6875

Oil volumne l ca. 15

Viscosity 40°C cSt 320

3

1

2

4

Loader transmission

Loader transmission right

1. Spur gear 2. Bevel gear 3. E-Motor, 36 [kW] 4. Loader star


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2.4 Chain conveyor The conveyor is rear driven by two 36 kW electric motor with the gear box posi-tioned on the rear end of the conveyor. The vertical movements are performed by two hydraulic cylinders. The horizontal movement is performed by one hydraulic cylinder. The chain is a standard 3” pitch x 29.0 [in] wide continuous Miner flight chain.

1 Front part

2 Rear part

3 Swivel part

4 Driving station

5 Lifting cylinder, 2x (vertical)

6 Swivel cylinder (horizontal)

7 Slidestone conveyor

8 Chain

9 Tensioning device

7

3

8

2

1

6

5

4

9


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2.5 Track equipment

The crawler track assembly is of rugged design to suit toughest mining conditions and is totally enclosed to keep out dirt. Each of the track assemblies consists of take-up pulley, take-up sprockets, drive sprocket, drive unit and crawler. The centre part of the track assembly moves on wear-resistant slides. The crawler system is driven by two hydraulic motors with multiple disk brake which is hydraulically released. In case of a hydraulic pressure drop the brakes immediately respond and bring the MINER to a standstill.

Traction force [kN/track] 300

Tramming speed, variable [m/min] 5,5 or 11

The track chains are tensioned via cylinders.

(1) Frame

2 Track frame right/left

3 Guide bar right/left

4 Stabiliser

5 Hydraulic motor

6 Gear with brake

7 Track chain

8 Deflection roller

9 Drive sprocket

3

6 (1)

2

5 4

7 8

9


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2.5.1 Track transmission The hydraulic motor is directly flanged to the gear. Power drive over two spur gears and two planetary gears. Technical data Input power kW 59

Input speed [rpm] 870 to 1740

Input torque, max Nm 550

Gear transmission ratio, i 180,64

Output speed [rpm] 4.8 – 9.6

Output torque, max Nm 99000

Gear oil quantity l 15

Weight kg 353

Track transmission


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2.6 Frame

The frame is a one piece steel structure. It carries all other assembly groups.

1 Frame

2 Track frame right/left

3 Sump cylinder

4 Rear stabiliser

5 Guide bar

2.6.1 Rear stabiliser (stab jack) The supports are integrated in the deflector. It stabilises the machine during cut-ting and prevents collisions with other vehicles. The supports on the right and left side can be individually lifted and lowered with the aid of hydraulic cylinders. The stabiliser jacks base are 1600 mm, the stroke is 530 mm. Maximum limit under floor 300 mm. The purpose of the stab shoe is to transfer machine weight to the front of the machine to assist in shearing down into the face. In addition, it provides solid support for the rear of the machine which will attempt to lower during the shear down cycle. The stab jack can also be used as a service jack to raise the machine for maintenance.

1

2

1

2

5

3

4

1. Cylinder

2. Skid


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2.7 Electric system • The electrical equipment is designed to FLP standard. The electric equipment of the ABM25, is designed to work on 1000 [V] / 50 [Hz]. The electric equipment is based on the application of the protective conductor system. All parts of the electric system which have body contact are connected with a protective conductor. All switch gear are placed in a flameproof (FLP) enclosure (machine distributor) to where motors, lightening, intrinsically safe control system and trailing calbe are connected to. The electrical equipment incorporates latest technology with respect to

• health monitoring, • sumping speed control depend-

ing on current draw of cutter and loader drives,

• profile control system etc., • radio remote control system, • optional methane monitoring.

2.7.1 Electric Drive All drive motors are of 3 phase squirrel cage type and direct on line started, which requires stable power supply.

Application Cooled Power kW Cutting drum water-cooled 270

Hydraulic drive water-cooled 132

Conveyor drive water-cooled 2 x 36

Loading drive, 2x water-cooled 2 x 36

Filler pump air-cooled 0,75


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2.8 Hydraulic System The hydraulic unit of the ALPINE BOLTER MINER comprises of the unpressur-ised hydraulic tank, the piston-pump group, the control system, the accessories as well as the pipe lines.

The hydraulic system operates with open circuits. The standard hydraulic com-ponents are designed for hydraulic oil. The hydraulic power pack is driven by one 132 kW electric motor. The bolting equipment comprises: 1 Hydraulic tank

2 Breather filter

3 Pump combination

4 Coupling

5 E-motor

6 Pressure filter

7 Filter indicator

8 Back flow filter

9 Heat exchanger

10 Solenoids

The system comprises four independent circuits:

• working circuit 1 (cylinder – grease pump), • working circuit 2 (water pump), • left and right tramming respectively drill rig circuits. The hydraulic motor and cylinders are controlled via spool valves (solenoid oper-ated).

5

4

3

7

1

6

89

2

10


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2.9 Bolting System The bolting system comprises four roof bolting rigs and two rib-bolter which al-lows rapid advance with simultaneous cutting and roof bolting and rib-bolting. The roof bolters are mounted on joints providing a wide range of bolt placements across the roadway width.

For conventional continuous miners it is difficult to sump in with crawler tracks if the coal is hard. Therefore the ABM25 uses the support canopy to hold the ma-chine in position while sumping the drum into the face per controlled cylinder force. The canopy also increases safety for operators. (For detailed description see chapter10, Anchor bolting system). The bolting equipment comprises:

1 four roof-bolters

2 two rib-bolters

3 stabilizing system with two canopy jacks

4 support canopy

5 two floor pads

6 two working platforms

7 two control panels for roof bolting

8 four control panels for rib bolting

• The roof bolting rigs can be tilted east- and west, plus north- and south. • The rib-bolters are located at the working platforms in the back of the opera-

tor. • The rib-bolters can be tilted up and down to put bolts at various heights.

24

3

1

1

5

5

6

78

8


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Sandvik Mining and Construction G.m.b.H., Alpinestrasse 1, A-8740 Zeltweg, Austria

www.miningandconstruction.sandvik.com

Documents

Bolter Miner ABM25-016