The new Caterpillar 785D Mining Truck incorporates new features to boost performance and reliability, reduce engine emissions, and enhance safety. The improvements also focus on component commonality to keep parts stocking and maintenance simple. The 785D builds on more than 20 years of proven performance for the 785 model. The 785D target payload ranges from 142 to 155 tons depending on the specific configuration. The range enables new trucks to integrate well with fleets of earlier 785s.
Using the latest technology, the Cat 3512C HD engine maintains fuel efficiency, delivers 1,348 net horsepower, and is compliant with U.S. EPA Tier II emissions standards. The engine is capable at altitudes up to 14,000 ft with no derate. With the change to a high displacement engine, engine life is extended.
Caterpillar also introduces the X body with the 785D. The X body provides mine specific options (e.g. liners, rail caps, sideboards, etc.) for new sites and contractors. The new body also provides greater volume—111 cubic yards (cu yd) vs. 102 cu yd for the dual slope body. Additional body choices are Mine Specific Body (MSD II), gateless coal body, and dual slope. The canopy of each of the bodies extends farther over the cab for greater protection. Additionally, the 785D has improved catwalks and a factory installed 600-mm diagonal stairway.
A number of changes extend reliability and durability: a new pump drive system provides continuous rear axle filtration. Benefits include cleaner oil, less downtime, and improved component life. Extended life disc brakes may achieve up to double the wear life of standard brakes and are resistant to glazing. The result is consistent braking power and reduced maintenance. New air intake and filters have a new seal, which provides easier servicing and lower maintenance costs. The Cat mechanical drive power train and power shift transmission provide superior operating efficiency and control on steep grades, in poor underfoot conditions and on haul roads with high rolling resistance. The 785D retains the Caterpillar mechanical power train that has enabled 785 models to achieve high productivity and reliability in challenging mining conditions around the world. www.cat.com
WEG has announced a program for ordering custom designed AC induction motors for a wide range of horsepower, voltage and speed ratings. Customization can include special shafts, special sealing or ventilation, special insulation requirements, and other factors, allowing an industrial user to exactly replace a motor used in an existing machine or facility.
"Until now, customers with an old nonstandard size motor were faced with a challenge–either modify a piece of machinery to accept a new standard size motor or continue to rewind the existing motor even as its performance continued to decline," explained Gerardo Elias, Marketing Manager. "Our new Custom motor program will enable these users to exactly replace or even upgrade an existing motor within the physical limits of their machinery or process."
Elias noted that WEG had a long tradition for building custom motors. "For example, our motor experts designed and installed the world’s largest induction motor at the Collahuasi mine in northern Chile to drive long conveyor belts removing copper ore and overburden. This motor weighed 15,000 kg and delivered 2,788 HP with an efficiency of 97.5%. And while not every custom motor will be this large, we are committed to meeting our customers needs going forward." www.wegelectric.com
Custom bar rail liners made of a long-wearing polyurethane compound are now available from W.S. Tyler. Tyrethane Bar Rail Liners are designed to protect tension poly screens and extend the service life of traditional wire mesh screens. They have 20 to 30 times greater service life of inexpensive rubber liners. Tyrethane Bar Rail Liners are used to support all metal media options, including perforated plate, wire, and other metal screens. This translates into less down time and lower production costs. Tyrethane Bar Rail Liners are easy to install and are available in 4 ft, 5 ft, and 6ft lengths, for a variety of steel bar widths. The liners can be used on any OEM vibrating screens. W.S. Tyler offers Tyrethane Bar Rail Liners at no charge when purchasing the company’s Ty-Max Tension Polyurethane Screen Panels. W.S. Tyler offers a complete line of polyurethane screening products, including panels, liners, and accessories. www.wstyler.com
HAWE Hydraulics, a leading supplier of sophisticated controls to the mobile and industrial markets, offers its PSL proportional directional spool valve, ideal for constant delivery pump systems. Adhering to the load-sensing principle, these spool valves serve to control the direction of motion while delivering infinite speed control for hydraulic consumers regardless of load type and weight. With the option of a valve bank or manifold mounting design and several available actuation types, the PSL is well-suited for a wide array of mobile hydraulic applications. www.hawehydraulics.com
The TA10 Big Red Series air winch has been designed for improved performance by incorporating a high capacity air motor into the unit which provides higher line pull capacity while maintaining faster line speeds. Performance ratings include first layer and full drum load capacities of 37,000 and 21,800 lb along with a maximum line speed of 34 fpm. Among its many design changes, the new series incorporates reversible band brake and disc brake assemblies and an innovative revolving cable anchor. The cable anchor accommodates wire rope diameters ranging from ¾ inch to 1 ¼ inch and facilitates winding of wire rope from either direction. www.thern.com
Cat Announces Options for Repairing Machine Control and Guidance Systems
Caterpillar offers new repair options to keep Cat machine control and guidance systems up and running and owning and operating costs down. Two economical solutions, repairing components or using remanufactured ones, provide customers the flexibility to choose the option that best suits their needs. Caterpillar remanufactured components are available off the shelf, warranted, and are about half the price of new. Cat Reman machine control and guidance components incorporate all critical engineering updates as they are factory-remanufactured using genuine Caterpillar parts. Each remanufactured component is tested extensively to ensure same-as-new performance, and each comes with a same-as-new, one-year warranty. For repairs, factory-trained technicians at the Cat Machine Control & Guidance Repair Center rely on test systems that replicate real-world applications for accurate diagnosis of each problem and equally accurate repair estimates. Components are repaired to Caterpillar quality standards and are tested rigorously to ensure they meet those standards. Each repaired component has a 90-day parts and labor warranty. www.cat.com
Real-Time, Mobile and Wireless Audio-Video Communication
Video conferencing is now widely used in the mining industry. Multinational companies use it to communicate with international branch offices, enabling them to work with their staff, clients, and suppliers in different countries, and to cut the hassles, risks, and costs of business travel. However, despite its benefits, video conferencing also presents many limitations for mining companies. The fix environment design philosophy does not fit well the needs of many departments who need a true “in-the field mobility,” such as exploration teams, geologists, project engineers, inspectors, mine managers, mechanics, etc. With Frontline Communicator, mobile team members can now have bi-directional communication with experts, managers, system engineers, or a group from a distance and transmit video/images—no matter their location or for how long. Frontline Communicator is a robust, hands-free, wireless, and lightweight bi-directional audio-video communication system. Connecting to almost all IP Broadband Networks, it offers reliable voice, data, video/images communications from virtually anywhere on the planet while providing maximum mobility to the team. www.audisoft.net
Strix Systems, a worldwide leader in high-performance wireless mesh networking, and Dotworkz Systems announced the availability of the highest performance, Integrated Wireless Video Surveillance System (IWVS)—the industry's only integrated wireless mesh network system specifically designed for optimal high-quality delivery of IP video surveillance over wireless/WiFi mesh networks in a single easy to deploy packaged design. Strix Systems patented high performance hardware and software are integrated into the Dotworkz D2 unique vandal-tough weatherized enclosures for IP-enabled Intelligent Pan-Tilt-Zoom (PTZ) cameras. The integration of Strix Access/One Edge capabilities give the IWVS the ability to achieve robust, continuous high throughput and low latency via Strix intelligent radio algorithms that dynamically adjust to the environment. Maximum power enables the greatest signal strength, receive sensitivity and optimal channel selection for the robust wireless connectivity and highest achievable throughput. www.strixsystems.com
Strix Systems, a worldwide leader in high-performance wireless mesh networking, and Dotworkz Systems announced the availability of the highest performance, Integrated Wireless Video Surveillance System (IWVS)—the industry’s only integrated wireless mesh network system specifically designed for optimal high-quality delivery of IP video surveillance over wireless/WiFi mesh networks in a single easy to deploy packaged design. Strix Systems patented high performance hardware and software are integrated into the Dotworkz D2 unique vandal-tough weatherized enclosures for IP-enabled Intelligent Pan-Tilt-Zoom (PTZ) cameras. The integration of Strix Access/One Edge capabilities give the IWVS the ability to achieve robust, continuous high throughput and low latency via Strix intelligent radio algorithms that dynamically adjust to the environment. Maximum power enables the greatest signal strength, receive sensitivity and optimal channel selection for the robust wireless connectivity and highest achievable throughput. www.strixsystems.com
The ARMOR line of fully-rugged computing products includes the Convertible Notebook and the Tablet PC. These computers offer data protection technology, “anywhere” connectivity and sunlight readable display options.
ARMOR mobile computers combine advanced computing and communications technology with MIL-STD-810F durability and exceptional service, which includes a three-year comprehensive warranty and a direct line to customer support. These computers use Intel processing technology and offer a full array of communications options, including integrated Wi-Fi, Ethernet and a PCMCIA slot. Weighing just 5.2 lb, including batteries, the tablets and convertible notebooks go anywhere in support of any operation requiring mobility.
The C12 Convertible Notebook features a rugged, die-cast magnesium alloy case. These units have been extensively tested for drop-shock, moisture, temperature extremes and resistance to dust and vibration, providing IP 54 level protection from damaging elements. The 12.1-inch outdoor-viewable touch-screen display quickly transforms from a tablet-style computer to a compact notebook with a full-size keyboard. The X10 Tablet features a specially designed aluminum DuraCase chassis with ShutOut sealing technology that meets IP 66 level protection from dust, dirt, water and temperature extremes. In addition, the ARMOR X10 Tablet offers no-flap input connections and tool-free, hot-swappable battery access. Available in both touch screen and passive pen versions, the 10.4-inch LCD monitor uses backlight technology for enhanced indoor and outdoor viewability—even in direct sunlight. www.drsarmor.com
Easy to use and comfortable to wear, the Draeger X-plore 1700 range of Filtering Half Masks is ideal for use where particulates may present a respiratory hazard. Available in three-color-coded versions for easy identification, these lightweight, folded masks are designed to meet the needs of different applications and offer FFP1, 2 and 3 protection levels. Incorporating Synsafe filtering material for high filter efficiency and low breathing resistance, the X-plore 1700 also benefits from a soft, comfortable inner layer and a bend-to-fit nosepiece. www.draeger.com
Xstrata Coal’s Beltana Coal mine, one of Australia’s most productive longwall operations, recently selected Mine Site Technologies (MST) ICCL cap lamps and digital RFID tracking system to support their on-going safety initiatives. Xstrata Coal has long had a strong focus on safety to support their production efforts, and hence identified opportunities for further enhancing safety at Beltana by introducing the new generation of light weight cap lamps and implementing a tracking system at the same time.
After an extensive evaluation of available technologies, the ICCL cap lamps and RFID tagging system were selected. Key points for the decision included:
The ICCL cap lamps have been operating at a number of other coal mines near Beltana, including other Xstrata coal mines;
The detailed engineering design of the tracking solution based on 802.11 Digital Access Points and AeroScout Wi-Fi tags met all their requirements;
The RFID Tags are incorporated inside the ICCL cap lamp battery pack to ensure long term reliability and ensuring they are always with a person when they are underground;
MST has track record of implementing underground 802.11 based digital communication
infrastructure in a number of underground mines; and
Compatibility, and approved for use, with Airstream helmets.
The initial installation consists of 200 ICCL Wi-Fi RFID tags for the workforce; 50 self-contained tags on underground diesel vehicles; 18 dual wireless ImPact Access Points; and Full AeroScout MobileView user and management software. In addition to the importance of tracking people for safety, Beltana’s management justified the cap lamp upgrade and tracking system implementation based on several criteria. The ICCLs are approximately one third the weight of the existing lead-acid batteries in use at the mine. The cap lamp and tag is one integrated unit. It allows the mine to manage the vehicle fleet and control access control to ventilation districts. The digital network established for tracking can also used in other applications over time, such as VoIP telephones for mobile two-way communication. www.minesite.com.au
(Content from Feb. 2008 Coal Age. To apply for a free subscription, click here.)
Joy Mining Machinery’s largest and most powerful longwall shearer is scheduled to go into production at the world’s largest coal mining complex, Shenhua Energy Co., Ltd.’s Shendong Coal Branch operation. Joy said the 7LS7 shearer meets the demands of ever-increasing mining heights and longwall face widths worldwide; seams exceeding 6 meters (20 ft) and faces up to 400 m (1,312 ft), with 450 m (1,476 ft) a distinct possibility in the near future.
The 7LS7 has a 6.5 m (21.3 ft) cutting height, chassis height of 2.8 m (9.2 ft) and weighs 138 metric tons (152 tons). It has 860 kW (1,153 hp) ranging arms, two 150 kW (201 hp) motors and a 270 kW (362 hp) lump breaker, far surpassing the previously largest 110 kW (148 hp), and theoretical hourly production capacity exceeding 4,500 mt per hour (5,000 tph).
Complementing the 7LS7’s size and power is the JOY FACEBOSS, the company’s fully-integrated, logistical control link that monitors and controls every aspect of the longwall mining cycle, from shearer guidance to advancing of the shields, from cut sequence to power distribution and control.
One of the key benefits of the system is its large, full-color graphic display that can be toggled back and forth between English and the local language. Prior to this major breakthrough by Joy, the only language that could be displayed had been English. www.joy.com
The BOSS high-performance Power-V XT is a new multi-position snowplow with a 37-inch flared blade wing that improves snow discharge for maximum performance. Available in two models (the 98-inch XT and the 110-inch XT), the Power-V XT Extreme Duty Snowplow is designed for the toughest jobs. www.bossplow.com
The 2007 Frost & Sullivan Product Value Leadership of the Year Award in the motors and drives domain was presented to AEGIS Shaft Grounding Ring (SGR)-developed by Electro Static Technology, an ITW Co. The new AEGIS SGR Conductive MicroFiber shaft grounding brush prevents electrical damage to motor bearings by safely channeling harmful shaft currents to the ground, thereby protecting the motor and allied equipment, thus dramatically extending the service life of the motor.
The Maximus Series of totally portable, automated wheel wash systems are engineered specifically for tough applications in the field. It is an entirely above-ground system, which can be assembled, attached to power and water, and ready to operate in just hours. The system features a fully automated, closed-loop water recycling and solids separation process—so that water present at the site entrance does not create any additional issues. The Maximus Series offers one- and two-tire revolutions of cleaning in its standard models—with custom built units also being available. www.innovativeequipment.org
Superior Industries has developed an idler roll that promises to last three times longer than steel and cut operating costs significantly. Designed with a specially formulated high density polyethylene (HDPE) material, Moxie rolls have been developed to solve expensive problems caused by abrasive material and buildup. Moxie rolls are manufactured with the SpinGuard seal system. Moxie rolls are a quiet and lightweight alternative to steel that can be retrofit into any idler frame or bracket. They are designed for users who are frustrated with material sticking to steel rolls, causing uneven wear and belt misalignment. www.superior-ind.com
AGM USA recently unveiled the 40W water wagon, the safest, most rugged and durable watering equipment specifically designed to maneuver through the toughest jobsite conditions, according to the company. The patented uni-body design, along with the 6-wheel drive and 4-wheel braking system, significantly increases the Static Roll Threshold (SRT) making it one of the safest products in the water business today. The unique vertical and horizontal baffles, featuring one-way check valves, creates 20 separate compartments and prevents water surges within the empty portion of the tank. The 40W has the compliant Tier III Cat Engine and carries the Cat 740 truck warranty.
“The 40W Water Wagon will likely revolutionize jobsite water solutions in every application,” said Chuck Paugh, president, AGM USA. “We’re excited to introduce this unique ADT Water wagon to compliment our already existing line of water product solutions available exclusively through the Cat dealer network worldwide.” AGM has been manufacturing and selling water equipment and watering solutions around the world since 2003. www.agmamerica.com
The MineMapper uses the latest mobile laser scanning technology combined with high precision positioning systems to capture highly accurate and detailed measurements on the move. It is ideally suited for the mining environment as the system can be deployed on a range of vehicles to suit all terrains. When combined with 3D Laser Mapping’s SiteMonitor software it can automatically create detailed 3-D models of the mining operation including highly accurate depletion surveys, slope stability models, stockpile measurements, and mine wide terrain map updates. www.3dlasermapping.com
The ProVision Proximity Detection Module protects capital assets by minimizing the risk of mining equipment accidents through advanced GPS-tracking technology. Using the module, operators receive real-time notifications of unsafe proximity to hazards. The system is currently functioning on some of the world’s top producing copper and iron ore mine sites.
The Proximity Detection Module has a three-level alarm system. The first-level alarm, which consists of a text message and a short beep being sent to the operator, is triggered upon detection of equipment or hazards within the equipment’s safe zone. If the detected equipment or hazard encroaches further into the safe zone, the system then triggers the second- and third-level alarms. The third-level alarm is continuous and will not cease until the danger is averted.
The Modular ProVision system operates on the MasterLink communication architecture and integrates seamlessly with the DISPATCH system. The system is also available for shovels, excavators, drills, and dozers. www.modularmining.com
DBT Plow System Sets New Chinese Production Record
A fully automated plow system supplied by Bucyrus DBT and commissioned at the Jinhuagong mine in China in 2005 is setting production records. Established in 1956, Jinhuagong coal mine is located 12 km west of Datong in the north of China. It had an annual output of 4.25 million metric tons (mt) in 2005 and is a key coal mine of Datong Coal Mine Group. The mine produces high-quality steam coal.
With an uptime of more than 95%, the plow system—a DBT Gleithobel GH 38 with 800 kW (1,080 hp) of cutting power and equipped with the PF 3/822 plow running track—achieved the best shift output of 3,760 mt in July 2007. The best daily output reached 5,700 mt. These are both new mine records. In July, the plow team safely mined 100,031 mt of raw coal, a new record for the plow working team at the mine. This achievement is outstanding given that the longwall is operating in very hard coal. The face is 200 m long and the seam varies in thickness from 1.35 m to 1.5 m.
In addition to the Gleithobel plow, the longwall system comprises the state-of-the-art DBT PM 4 shield control system and plow control technology for complete automation, requiring no operators at the face; a big boost for increased mine safety. The plow is driven by two 400 kW motors via a 38 mm plow chain. The conveying system, speed of plow, depth of cut, and shield support controls are all tailored to Jinhuagong mine conditions to maximize performance and safety. DBT tailors all of its systems to the specific requirements of each underground operation, using its decade-long experienced engineering workforce and its countless references around the globe, including eight fully automated plow systems sold to China since 1999. www.dbt.de
With its powerful 1.86 gigahertz Intel Mobile processor, the new Simatic Panel PC 577B from Siemens Automation and Drives (A&D) provides outstanding computing power for industrial applications. The panel, which is only 14 centimeters deep, has a main memory of 512 megabytes. This can be increased up to four gigabytes. The diverse basic features of the Simatic Panel PC 577B include an 80-gigabyte hard disk, two Ethernet interfaces, a DVD burner, one USB interface on the front and four on the back, and two PCI extension slots. The touchscreen display is available in sizes 12, 15, and 19 inches. The panel PC has a high degree of protection of IP 65/NEMA4 on the front and is designed for temperatures up to 45ºC. All versions of the PC 577B panel can be supplied ex warehouse. www.siemens.com/simatic-panel-pc
The ST1000 air starter features 8% more horsepower than other offset turbine starters in the same range, according to the manufacturer. It also delivers up to 25% more torque than other models. The new air starter consumes 30% less air or gas than previous Ingersoll Rand models and is 30% more efficient than competitive models, dramatically reducing its cost-of-ownership and emissions. The ST1000 uses fewer parts for simpler operation and repair. The starter’s slip clutch design ensures that no soft-start valve or other special controls are required, reducing shock-loading and providing better protection. This design helps operators prevent broken pinions, shafts, and other common equipment breakdowns. Ceramic hybrid bearings increase starter component life by ensuring less friction and cooler running. Bearings are grease-sealed for life and require no motor lubrication, providing cleaner operation and easier serviceability. The ST1000 also features the same inlet and outlet locations as the ST700 and ST900 air starters for easy change-out. www.ingersollrand.com
Biomarine has been awarded certification by the National Institute for Occupational Health and Safety (NIOSH) for its all-new, state-of-the-art Biomarine BioPak 240 Revolution 4-Hour Rebreather. The NIOSH certification includes an approval to 42CFR Part 84 for the BioPak 240 Revolution’s system as well as the Mine Safety and Health Administration approval to 30CFR Part 18 for the electronic monitoring system.
The BioPak 240 Revolution was developed after exhaustive R&D and focus panel testing with a wide variety of rescue personnel. It is the industry’s most advanced and easiest to use long duration rebreather on the market. With its disposable solid CO2 scrubbers and quick-change coolant systems, the 240 Revolution represents a significant advancement in closed circuit, self-contained breathing apparatus technology in over a decade.
A 6-liter tidal volume delivers the industry’s lowest closed-circuit breathing resistance at all work rates. This makes breathing more comfortable and less stressful. The unit’s large breathing chamber incorporates three springs for guaranteed positive pressure. www.biopak240r.com
Sioux’s custom high-pressure washers for the mining industry can be easily and safely used in underground and surface mines to clean dirt, oil, grease and grime off machinery. These all-electric pressure washers and steam cleaners heat the cleaning water with electricity, eliminating fumes and flames. www.sioux.com
IDL 6.4 is software that supports data visualization in an analysis environment. It provides new data transfer utilities that improve the ability for users to quickly and easily access a wide variety of data. Users can receive data from remote servers and write data files to a disk at a remote location using the most common protocols, such as HTTP and FTP. In addition, IDL 6.4 introduces support that allows IDL users to query and retrieve remote data from Open Geospatial Consortium (OGC) geodatabases directly from within IDL. www.ittvis.com/idl/pr
Cat Introduces New 993K Wheel Loader Designed for Tough Digging and Fast Loading in Mining Operations
The Cat 993K Wheel Loader is a totally new model and offers a new size class in the Caterpillar line. The 25-ton loader capacity matches well with the Cat 777 and 785 haul trucks. Built on an all-new platform, the new loader features Z-bar linkage, hydraulics, and power train that deliver superior penetration into the pile and high breakout forces—20% more than the 992G. The increased performance and capacity result in a 15% to 20% improvement in productivity compared to the 992G.
The new loader also features the Cat C32 ACERT engine for increased performance and U.S. EPA Tier 2/EU Stage IIA emissions compliance. It produces net power of 950 horsepower (708 kW). The 993K also offers innovative solutions to ease maintenance and boost reliability. For example, the Cat exclusive sleeve bearing pins eliminate the need for daily greasing of the front linkage. To lower life cycle costs, the 993K is designed to meet mining customer rebuild requirements and have an estimated 45,000-hour structure life.
The loader design also emphasizes operator safety and comfort. The wider platform allows a spacious cab, and a trainer seat is standard equipment. Seat-mounted controls allow precise operation even on rough ground, and electronically controlled lift and bucket tilt detents can be set from the operator seat. The optional rearview camera increases the view behind the machine. An optional rear access system replaces the left hand ladder and lifts the operator to and from the cab.
The power train and hydraulics are designed to deliver high productivity and low cost per ton. As compared to the 3508B engine used in previous mining loaders, the C32 engine delivers 19% more power and a 5% increase in fuel efficiency. The proven C32 also powers several other Caterpillar mining machines, which simplifies parts inventory management.
The 993K features the next generation modular radiator (NGMR), which has copper fins for superior heat exchange capabilities. The design and construction minimizes space required for the cooling package and allows enhanced sight lines to the rear.
Positive flow control (PFC) hydraulics is the next generation of load-sensing hydraulics. Additional sensors at the pumps provide enhanced responsiveness that the operator can feel and use. The full return flow filtration system filters 100% of the implement oil return flow to 6 microns for extended component life and increased uptime. The optional deluxe filtration system prevents downstream contamination in case of a failure.
