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Műszaki Tudományos Közlemények vol. 16. (2022) 5–9.
DOI: Hungarian: https://doi.org/10.33895/mtk-2022.16.02
English: https://doi.org/10.33894/mtk-2022.16.02
MODELLING AND SIMULATION OF THE STRUCTURAL
ELEMENTS AND THE OPERATING PROCESSES OF MINING
MACHINES
Endre ANDRÁS
University of Petroșani, Faculty ofMechanical and electrical Engineering, Departmen of Mechanical,
Industrial and Transportation Engineering, Petroșani, Romania, andrei.andras@gmail.com
Abstract
The paper deals with theoretical bases of the implementation in mining equipment design of up-to-date
methods using modelling and simulation, supported by examples of personal research. This has become nec-
essary due to the structural complexity of this equipment, and the variety and aggressiveness of their operat-
ing environment. The presented examples refer to different kinds of the equipment used in the mechanical
extraction of mineral raw materials, from overall system to working part or tool.
Keywords: mining equipment, modelling, simulation, design.
1. Introduction
It is a well-known fact that the structural comp-
lexity of the machines and equipment used in mi-
ning, along with the variety and aggressiveness of
their operating environment, have caused delays
in the technological evolution encouraged by the
achievements of modern science.
Taking into account the continuous develop-
ment of technical software specializing in model-
ling and simulation, there are also a wide range of
options for an integrated approach to the mecha-
nical systems of such machines and equipment.
The extraction of mineral raw materials, alt-
hough based on simple basic operations, requires
target-specic machines and equipment. Mining
technology, both underground and open pit, is ba-
sed on three basic operations - wining, - loading/
hauling - cavity support or slope stabilisation.
Mining machines perform the mechanization of
these basic operations.
In order to get an image of the large variety,
complexity, scale, dimension, weight and sophis-
tication, we present below some examples of
typical, up-to -date mining equipment, used for
different operations in different technologies, in
open pit or underground environments.
Figure 1. presents the main equipment used in
open pit coal mining, the Bucket wheel excavator.
In the Figure 2. the longwall shearer - loader is
presented, used for wining coal in underground
mining, by longwall technology. Figure 3 pre-
sents the continuous miner, used in wining coal
in underground mining, by room-pillar method.
Figure 4 presents the support shield, used in sup-
porting the cavity in longwall faces.
In the underground mining, in order to reach
the mineral reserve, some roadways (tunnels)
are headed, with the use of specic machines. Fi-
gure 5 presents the roadheader, for continuous
driving, while Figure 6 shows the drilling jumbo,
used in drilling-blasting road driving technology.
We can notice some peculiarity of mining ma-
chines due to the fact that mechanization follows
the technological process and ts with it, such as:
– increasing the performance requires size and
weight growth:
– the moving workplace places machine mobi-
lity among the important features;
– each operation requires a separate execution
tool;
– a compromise must be reached between speci-
alization and universality.
András E. – Műszaki Tudományos Közlemények 16. (2022)
6
2. Modelling of the Load-bearing Struc-
ture of the Bucket Wheel Excavators
In the following we present the application of
the modelling of the load-bearing structure of the
Bucket Wheel Excavator (BWE), and the simula-
tion based on it.
In Figure 7 is shown the load-bearing structure,
namely the boom, which supports the main wor-
king part, the bucket wheel (Figure 8), and per-
forms the vertical and horizontal motion in order
to realize the necessary kinematics.
The modelling and the simulation, is preceded
by lab and in situ data acquisition and processing.
The methods based on closed form mathemati-
cal formulas or assumptions can give only peak or
average values of forces, torques, stresses, power
and other parameters. The inconsistency of these
data can lead to under or over-dimensioning of
the considered parts.
Modeling and simulation technical software
makes possible the study and analysis of mechan-
ical phenomena by way of avoiding simplistic hy-
potheses and closed form equations.
In this approach, the SOLIDWORKS software
package was applied on the model of the bucket
wheel. Based on the developed model (Figure 9),
Figure 1. Bucket wheel excavator used in open pit
coal mines.
Figure 2. Longwall shearer - loader.
Figure 3. Continuous miner.
Figure 4. Longwall support shields.
Figure 6. Drilling jumbo.
Figure 5. Roadheader.
András E. – Műszaki Tudományos Közlemények 16. (2022) 7
and knowing the laws of change of the cutting
and lifting force values, the variation of the two
forces over time was determined (Figure 10).
The result of these loads was used as excitation
on the boom structure (Figure 11) in further si-
mulations (Figure 12).
Thus, for example, we examined the vibra-
tions of the boom structure. Some of the results
are presented in Figures 13 and 14. They are
the same as the results obtained by the measure-
ments.
Figure 7. The load bearing structure of the BWE
Figure 8. The bucket wheel in operation mounted on
the boom
Figure 9. Detailed modell of the boom.
Figure 10. Generating on the model the cutting and
loading forces variation in time
Figure 11. Detailed model of the bucket wheel.
Figure 12. Resultant force variation during one cut
Figure 13. Frequency response spectrum.
András E. – Műszaki Tudományos Közlemények 16. (2022)
8
Data was processed with the use of two procedu-
res. The modal analysis was completed by taking
into consideration a global damping coecient.
On the other hand, the response function analysis
was performed by taking into account the Rayle-
igh's damping coecients. Both showed that the
maximum deection corresponds to the frequ-
ency of 2.07 Hz. Since the excitatory frequency is
1.25 Hz, resonance phenomenon may be avoided
with a consistent probability.[1, 2].
3. The modelling of the energy and
power demand of the Bucket Wheel
Excavator
Based on the model of the excavator, we have
developed a new method for calculating the
energy and power needs of Bucket Wheel Exca-
vator. [3]
Using CAD, the method presented determines
the amount of rock extracted during swinging
(Figure 15). Knowing the specic energy dem-
and, we calculated the energy and performance
parameters.
The results shown acceptable deviations from
the values calculated by the traditional method.
Since the proposed method is based on numerical
calculations, it can be applied to any BWE, among
various rock-types and working place parame-
ters.
4. Modelling of the working tool of the
Bucket Wheel Excavators
The benets of modelling are also highlighted
by the optimization of the sizing of the tooth whi-
ch is the working tool of the bucket. [4]
Thus, knowing the forces acting on the tooth,
using the nite element method and numerical
modelling, we established the optimal shape.
The results are shown in Figures 16 and 17.
5. Conclusions
The recent advances in modelling software offer
a wide range of options for an integrated approa-
ch to the design of mechanical systems of mining
machines and equipment, by modelling and si-
mulation.
Using the SOLIDWORKS software package, we
have developed a model of the bucket wheel. Ba-
sed on this model, we have performed different
simulations, from overall system to working parts
and tools.
Figure 14. Frequency response diagram.
Figure 15. The volume of cut during one swelling of
the boom.
Figure 16. Optimal shape of the tooth’s longitudinal
cross section obtained by analitical model-
ling.
Figure 17. Optimal shape of the tooth by FEM.
András E. – Műszaki Tudományos Közlemények 16. (2022) 9
References
[1] Popescu F. D., Radu S. M., Andras A., Brinas I :
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https://doi.org/10.3390/en14133892
[4] Andraş A., Andraş I., Tomuş O.B.: Optimization of
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