New technology to be displayed at bauma 2010

Exhibitors are already gearing up for bauma 2010 - teh world's largest display of constructrion, mining and tunnelling equipment

MUNICH - 

Germany's bauma, a three yearly event held in Munich and which will take place this year from April 19^th to 25th, is the world's largest construction and mining showplace with over 3,000 exhibitors occupying over 550,000 square metres of exhibit space.  Manufacturers are already gearing up their exhibits for the event and some of those which may be of interest to the mining sector are as follows:
 
The new hydraulic hammer presented at bauma by Atlas Copco is fitted with PowerAdapt, a system which automatically switches the machine off when the oil pressure becomes too high. This is particularly useful when the hammer is being used on different carrier equipment, because hydraulic hammers can become overloaded hydraulically if the oil pressure on the carrier equipment is not set correctly. As these hammers are subject to the toughest of conditions, the improved guide system brings improved stability and resistance. With a weight of around 3150 kg, the HB 3100 can be fitted to carrier equipment in the 30- to 52-tonne class.
 
The 'down-the-hole flushing head for dry-drilling rods' from Bauer Maschinen GmbH was nominated for the bauma Innovation Award 2010, in the 'Machine Component' category. When this down-the-hole flushing head reaches a hard layer of rock it can be fitted to the Kelly bar together with a disc cutter full-face cutterhead positioned underneath or with a disc cutter core drill. When the drilling tool is standing on the base of the drill hole and is pressed via the thrust of the drilling device, a lever mechanism spreads the stator of the down-the-hole flushing head against the wall of the drill hole. This ensures that the connection to the compressed air pipe does not rotate along with the rotor which passes on the rotation of the Kelly bar to the drilling tool.
 
With some types of rock, the drill rods have to be cleaned each time they are pulled out. And even in the dirty conditions of mining, quarrying or building sites, machinery needs a regular wash. Portable cleaning systems are ideal for this application. One such new system, exhibited for the first time at bauma 2010, is a hot-water high-pressure cleaner HWBBW50Kpi from Brendon Powerwashers. A diesel-driven water-plate heat exchanger heats the water to 78°C. The system uses a part of the waste heat from the boiler to pre-warm the buffer tank for hot water. The high-pressure cleaner works with maximum pressures of 238 to 340 bar and a flow of 12.5 l/min.
 
The longwall conveyor and plow-drive control system PMC-D/V for underground mining was further developed by Bucyrus and now offers vibration management (VM) for better protection of mining equipment. The system, called VibraGuard, enables trained personnel to predict machine component wear, avoid unplanned downtimes and set alarms to warn the operator about the danger of damage to the monitored machine components. To meet customer wishes, the functionality of the PMC-D system has been extended. A digital signal processor converts incoming acceleration data into spectrum data, which are then transferred to a service PC. The data are evaluated and visualised by the VibraGuard visualisation software installed on the PC.
 
Continental is offering its tyres for heavy-duty earthmoving machinery under the brand name of Simex. The wide-based tyre Simex SE65 is especially suited for use with wheel loaders and bulldozers which are used in the toughest conditions in quarries or in mining. These tyres have a very deep tread. The almost flat profile ensures good load distribution and the opposing cross grooves give excellent traction. The rubber mix used is largely resistant to cuts and abrasion.
 
The automated shearer loader SL750 EIControlPlus from Eickhoff Bergbautechnik GmbH has been nominated for a bauma Innovation Award in the 'Machine' category. Using this it is now for the first time possible to do automatic longwalling in coal mines, where the operator is merely monitoring operations, in a secure, unpolluted environment. Thanks to a system of interlinked infrared cameras with image processing and body sensors, environmental monitors, millimetre wave radar to avoid collisions and visual cameras, the machine can independently recognise the deposit boundaries, thus delivering automatic control of all operations in the extraction process along the coal seam. Unnecessary extraction of undesired surrounding rock is thus avoided. This saves additional energy input and carbon emissions.
 
The new generation of load-haul dumps (LHDs) with efficient drive system (EDS) from GHH Fahrzeuge GmbH for tunnel/gallery construction and mining offer advantages in terms of their small dimensions, energy efficiency, improved productivity and ergonomically designed workplaces. As the road conditions in tunnelling and driving demand that when both loading and braking all four wheels must transmit drive and braking force, the axles are mechanically connected with each other. The combination of a modern diesel engine, hydrostatic power transmission and mechanical drive concept brings fuel savings, improved user comfort and a reduction in emissions in underground applications.
 
Haver Engineering Meißen (HEM) does research and development work in the areas of agglomeration/pelletizing and cleaning plant for building materials and minerals on behalf of the HAVER & BOECKER international group. HEM is an affiliated institute of the Technische Universität Bergakademie Freiberg. As a result the latest findings from scientific research are used in their project work. Scientists from the university are now joining the team of experienced engineers and specialists, and new resources are being made available. HEM supports its customers from concept phase through to production, along the entire product-development process, in the development of components, machinery and plant. In each project the customers benefit from the development competence and experience of the company and from the latest technological developments, materials and findings from the Technical University.
 
Herrenknecht AG delivers tunnel boring systems for diameters from 0.10 metres to 19 metres. The range of products includes custom-made machinery for transport tunnels as well as supply and disposal tunnels. The company has now developed Direct Pipe, a process that combines the advantages of microtunnelling and horizontal directional drilling (HDD): in just one continuous operation, a borehole is drilled and a prefabricated pipeline inserted. As with pipe jacking, earth excavation is by means of a microtunnelling machine. The force required to feed the pipeline forward is exerted by a new type of feed developed by Herrenknecht, called the Pipe Thruster.
 
At bauma Liebherr will be presenting a number of new developments for applications in mining and tunnelling. Designed for use in extraction operations, the crawler excavator R 954 C SHD achieves a digging force of up to 435 kN / 44.3 tonnes and breakout forces of up to 355 kN / 36.2 t. Its wear-resistant shovel has a capacity of 3.5 m³. Because of the shovel form, good penetration into the material and a high level of filling is guaranteed. Two different requirements profiles apply to the use of excavators for tunnelling: on the one hand very high-performance excavators are needed for the excavation of tunnels with large cross sections. On the other, short-tail excavators are increasingly in demand for driving out railway tunnels or auxiliary tunnels, as well as for renovation work in existing tunnels. For over 20 years Liebherr has been manufacturing hydraulic excavators for use in tunnel construction. The new R 924 Compact Tunnel achieves an advance of up to 2.50 m. Its maximum digging force is 135 kN and it has a maximum breakout force of 85 kN.
 
To cut through steel cord conveyor belts, you need the right tools. One such tool, developed specially for the job, comes from NILOS GmbH & Co. KG - its belt-cutter ROTOCUT. Nilos supplies two electrically operated versions, the RCE 20 and the RCE 40, plus a mechanical version RCM 20. As the latter is not electrical, it is suitable for use in underground mining. The toothed cutting wheel cuts into the belt from above and in doing so sets the two lower, smooth cutting wheels in motion: the belt is cut through shear action. The teeth in the upper toothed cutting discs are arranged in such a way that one steel cord fits between two teeth, the cord being sheared as the disc rotates. This happens also with the manual lever drive of the RCM 20 which can be operated without the need for great force; an amazing feat in view of the thickness of the steel cables! This cutting technique has been patented by NILOS GmbH & Co. KG.
 
Sandvik Mining and Construction will be presenting their new impact crusher QI 240 at bauma. In development the focus was primarily on the crushing of recycling or building materials. But because of its compact design, the model is also suited for use in smaller mines and quarries where there is little space to manoeuvre, but where first-class product quality and high throughput are required. The QI 240 is the first of a new series of mobile crushers and screens that Sandvik will be launching in the coming months.
 
In quarrying, mining of solid rock and on building sites, powerful crushers are what´s needed. SBM Mineral Processing GmbH has redesigned its universal crusher series and brought them together in the new Series 13. The 13/16/4 RHSMK-3 impact crusher has a fully hydraulic impact apron. This model is based on a robust, but effective combination of mechanical and hydraulic adjustment and guarantees good protection when foreign bodies enter the crushing chamber.
 
Tenova TAKRAF has developed a pit-crushing system consisting of a mobile crusher, transfer conveyor and spreader. The mobile crusher, from the TMCS series, was designed for a new coal mine in Queensland, Australia. It works with a maximum crushing power of 12,000 t/h, which probably makes it the number one mobile crusher worldwide. It can break down hard stone material (e.g. basalt) with lengths of up to 1200 mm to a transportable grain size of 350 mm which is suitable for conveyor transportation. In face operations the TMCS 12000 moves along the face with the excavator and passes the material extracted either direct or via a transfer conveyor to the face conveyor. Using mobile crusher systems means there is no need for heavy-duty vehicles to remove the overburden. This considerably reduces not only the road-building construction costs in mining, but also diesel and tyre consumption, staffing costs and not least carbon emissions.

The surface miners from Wirtgen GmbH for mining minerals have cutting widths from 2.20 to 4.20 m and cutting depths of 20 to 83 cm. The 4200 SM model is being presented at bauma for the first time. This is available in two configurations for use in hard and soft stone: for soft-stone applications up to a single-axle compression strength of 50 Mpa, the 4200 SM is fitted with a cutting module of 4.20 m working width with a larger diameter cutting circle. This enables a cutting depth of up to 83 cm. In addition a unit with a cutting width of 4.20 m and a cutting depth of 65 cm of hard stone, with a single-axis compression strength of 30 to 80 Mpa is available for the largest Wirtgen miner.

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