Krzysztof Krauze’s research while affiliated with AGH University of Krakow and other places

A central engineering concern in the use of such winches is their energy intensity, which is significantly influenced by operational factors such as the length and gradient of the transport route, the transported weight, and the target hauling velocity. These variables directly affect the drive system’s load and thus the power demand of the motor, which represents the primary component of the system’s energy consumption. While manufacturers typically provide structural, kinematic, and power-related specifications, the user must evaluate whether a given winch can operate efficiently within the energy constraints imposed by specific site conditions. To aid in this assessment, an analytical model, along with a computational software tool, has been developed. This solution enables the continuous determination of essential parameters, with particular attention paid to the energy requirements of the system, supporting informed selection and implementation of winches with appropriately rated motors to optimize energy consumption. For the analyzed case, it was calculated that doubling the transport distance results in an increase in energy consumption of approximately 50%. Moreover, an increase in the velocity of the transported weight by only 0.5 m/s leads to a rise in energy consumption of approximately 25%.

Belt conveyors, owing to their simple construction, high reliability and relatively low energy consumption, are the basic means of transporting loose and granular materials. Currently, thanks to continuous development, belt conveyors can reach a length of up to several kilometres, and their belt width can be more than two meters. Such possibilities are achieved thanks to increasingly better belts and drives. However, the most common are short belt conveyors with a length of up to 40 m and belt widths of up to 1 m, frequently referred to as belt feeders. Apart from the mining industry, they are widely used in power engineering, metallurgy and other industries (chemical plants, trans-shipment ports, storage yards, etc.). The design of machines, including belt feeders, is based on calculations. Modern design in technology is based on advanced computational methods and the possibilities of computer technology. Multi-variant simulation calculations are necessary, especially in the case of belt feeders, where none of the devices—despite the use of typical elements and subassemblies—are a repeatable solution. Only this procedure guarantees the selection of rational solutions already at the early stages of design. Therefore, in this article, an analytical model of a typical belt feeder was developed and its stability and forces in the supports were determined. This allowed the development of an application for testing the stability of the belt feeder at the design stage or when introducing structural changes.

The cutting tools in mining industry are especially prone to rapid wear, since most of the rocks exhibit aggressive abrasion attributes. A typical representative of fast wearing mining end-tools is a conical pick (also known as tangential-rotary cutter). In order to decrease the premature deterioration, the manufacturers and users tend to enhance the lifespan of the tool by wide range of approaches, namely heat treatment, chemical treatment, burnishing, hardfacing etc. In order to estimate the wear rate of a given pick one has to select appropriate procedure and method of evaluation. By this time, most commonly applied method is to estimate the wear rate basing on mass loss measurements of the tools being exploited with constant cutting parameters and fixed conditions. The Authors proposed also a new method of volumetric wear assessment, basing of three-dimensional photogrammetric scanning and compared the results with the outcome of traditional mass wear evaluation of the same sets of tools. Additionally, this paper contains recommendations regarding both approaches (volumetric and mass), especially focusing on the possibilities of the new method concerning measurements of the manufactured tool.

Shifting masses in a confined space in the company of other machines and devices, which limits the manoeuvring and transport area, poses a significant problem in every field of industry, especially with underground mining. The works involved in transporting and manoeuvring masses in underground workings are challenging and are most often performed using various auxiliary machines or manually. Hence the need arose to develop a device carrying out activities related to the shifting of masses with the assumed maximum value. The device was created as a result of cooperation between FAMA sp. z o.o. and the AGH University of Science and Technology in Kraków, Poland. The mining modular transport and assembly unit (MZT-M) enables assembling and transporting various masses, especially the elements of the roadway support in the face. The primary function of this device is its movement in the excavation along with the transported mass and delivering it to a specific place. Therefore, an important issue is to ensure the module’s stability in different phases of its operation (lifting, transport, manoeuvring, feeding, lowering) due to the limited space in the excavation. That is why an analytical model and specialised software were created to determine the design parameters of the device as a function of its operating phases, especially the counterweight’s mass. As previously mentioned, an analytical model (physical, mathematical) with equations and applications written in Microsoft Visual Studio and Matlab was used for this purpose. It is beneficial at the design or construction changes stage. Calculation results are documented in the form of numerical summaries and graphs.

The wearing of cutting tools is a bottleneck of many branches in the industry. However, the tools used in the mining sector are extraordinarily prone to rapid deterioration since many rocks exhibit aggressive abrasive properties. A typical example of a fast wearing cutting tool is a conical pick. It is used in the mining industry and other businesses requiring rock cutting, such as in roadworks and tunnelling. Both manufacturers and users attempt to find a way to enhance the lifespan of the working surface of conical picks via different approaches, namely heat treatment, chemical treatment, work hardening, and hardfacing, etc. To correctly estimate the resistance to abrasive wear for a particular conical pick, one must select appropriate procedures and methods. By this time, the most common estimation method is to measure the mass loss before and after cutting, preserving the specified and constant conditions. This method was developed for users (mines) and manufacturers of cutting tools, especially conical picks. Alternative methods of assessing the picks’ wear are also sought. In this paper, the authors perform additional volumetric loss measurements via a photogrammetric approach, which results in a 3D scan of brand-new and exploited conical pick. Three different sets of four picks were measured both in the domain of mass loss and volume loss, and the results were compared. Slight differences in parameters C2 and C3 were found. Additionally, the authors enclose recommendations regarding the proper use of the methods mentioned above, mainly focusing on the ability to perform linear and angular measurements of the tool performed on the 3D scan.

The cutting heads currently used in longwall shearers, roadheaders, road milling machines and excavators are equipped with cutting tools called picks. The most commonly applied are conical picks, less frequently—radial picks or tangent picks. The picks are detachably mounted in holders installed on the body of the cutting head, to which they are usually welded (shearers) or, less frequently, form-connected (road milling machines). The arrangement of picks and holders (positioning) on the body of the cutting head, according to a previously designed diagram (pick arrangement), enables extraction of the mineral with a specific width (web) and diameter (height). Ideally, the pick arrangement should generate the lowest cutting resistance, which loads the cutting machine. The pick arrangement is characterized by design parameters (number of holders, pitch in the line and between the cutting lines) and kinematic parameters (rotational speed and advance speed). The values of these parameters result mainly from the properties of the mineral and the type of mining machine. Therefore, the correct positioning of the holders on the cutting head and their setting (cutting angles) are vitally important. This applies to both the design and implementation stages. For this purpose, the authors first developed models of pick arrangements and, next, the algorithm and software enabling the determination of cutting resistance, both in terms of the average value and its variation. Then, based on the performed calculations and the obtained results, it can be assessed whether the cutting head and the pick arrangement are properly designed. As a result of the performed calculations and analysis of the test results, the average values of the cutting resistance moment and the cutting machine advance forces were determined. It was found that the proposed pick arrangements are characterized by similar values of moments and forces. The greatest differences were found in the variability of these parameters, which translates into the dynamics of the cutting machine operation.

The yielding arch support is transported and installed in the face with the use of auxiliary machines. These activities in underground mining cause many problems, which have as yet not been solved. Currently, transport and assembly are carried out manually, using the roadheader and suspended rail, or various types of mounting platforms. The analysis of the structure of the existing solutions resulted in the development of an original structure that met the requirements of Polish mines. Developed jointly by FAMA Sp. z o.o. and the AGH University of Science and Technology in Krakow, Poland, the mining modular transport and assembly unit (MZT-M) will enable the transport and assembly of support arches in the mining face. Additionally, it can also be used to reload works, which is related to the work ergonomics in underground coal mining, which is the main energy resource in Poland. The most important problem to be solved in the case of this manipulator, due to the limited space in the excavation, is how to ensure its stability during various phases of its operation. Therefore, analyses were carried out to find a solution, which resulted in determining specific conditions and design requirements related to the operation of this manipulator.

The roof support, especially the ŁP yielding steel arch support, is transported and assembled in the face with the use of auxiliary machines. This activity in Polish underground mines causes numerous problems, which until present have not been solved. Currently, transport and assembly are carried out manually, while the roadheader and suspended rail are used only to a small extent. Therefore, the modular installation and transport assembly was developed jointly by FAMA Sp. z o. o. and AGH University of Science and Technology. The solution in question enables performing a number of functions (including transport and assembly of all kinds of support arches), which are not available in currently manufactured equipment. The proposed manipulator solves numerous problems occurring during the installation of the steel arch support in an underground mining excavation and significantly improves the process of drilling galleries. This innovative solution considerably differs from the existing ones, and its greatest advantage is versatility with regard to the cross-section and equipment of the roadway, as well as a wide range of functions. In addition, it can also be used for reloading works. The modular installation and transport assembly together with a platform, a temporary mechanized roof support and a mining machine, make up a mechanizes roadheader complex, which enables continuous mining, loading and installing the permanent support in underground workings.

User’s choices of conical picks currently involve specifying their material and geometric parameters (functional requirements), incorporating the place and conditions of their work (operational requirements). The selection is usually made based on solely one criterion, which is the price. Thus, at the stage of both purchase and operation, the quality of picks, as well as their matching for a specific machine, are not assessed. The problem of defining whether the producer has fulfilled the user’s requirements arises only when the user questions the picks’ quality. Analysis of this problem has resulted in developing assumptions, concepts and research procedures based on the cutting process requirements. The procedure allows conducting tests to determine the geometric parameters of a pick, the type of material of the pick body and WC-Co insert, as well as the pick wear rate (intensity). The C2 index describes the wear rate (intensity)—the smaller its value, the slower the pick’s wear. Laboratory tests were carried out at the AGH University of Science and Technology in Kraków, Poland. Following the developed method and procedure, the quality of picks was precisely and unambiguously assessed. The C2 index, apart from testing the quality of picks, was also used to forecast their wear. Based on the C2 index, a method is proposed to estimate the wear rate of conical picks provided by different manufacturers and determine the acceptable unit price and operating costs. Thus, it is possible and reasonable to precisely define the investment requirements and appropriately select the pick. Relevant tests were carried out for eight different types of conical picks used in roadheaders, longwall shearers and shaft-boring roadheaders.

The article describes issues related to the development of a sensor measuring the distance from the end of the shield support canopy to the face of the longwall panel. The sensor's task is to detect rock falls because in such a case, empty spaces in the coal seam below the roof are generated. The sensor is a part of the system which task is to predict unfavourable behaviour of the longwall roof affecting the continuity of mining. Due to an untypical workplace and difficult conditions prevailing there, it was not possible to use a typical sensor. The ultrasonic technique was used for this purpose. The next research stages related to the development of the sensor were described. Tests of various types of ultrasonic transducers, working at different parameters, were described. Only transducers with a closed structure were considered because they can operate in the presence of high dustiness and humidity. The sensor casing was adapted to a specific type of shield support. The installation location should not be accidental, as an additional hinged shield is mounted at the end of the canopy, which is an obstacle in the measuring track and can even completely cover it, making measurements impossible. The sensor is mounted close to the side edge of the shield support canopy using small free space, enabling a measurement. Structural elements of the canopy are obstacles in the measuring track and are a source of interference of the received signals. The ultrasonic transducers are built-in tubes, which direct the ultrasonic wave and amplify the received signals. The results of laboratory tests of the model of the path measurement sensor are presented. They describe the impact of analysed aspects, i.e. the type of transducers used, the structure of the surface that the wave is reflected from and the mechanical solutions on the quality of received signals. A prototype of a sensor installed on shield support is presented.