Education Under Ground Mining E Book 02

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Second edition 2007www.atlascopco.com

Loading and Haulagein Underground Mining


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We always take a hard view on costs

Working with Atlas Copco means working with highlyproductive rock drilling solutions. It also means sharing acommon cost-cutting challenge. Like you, we are alwayslooking for new and effective ways to squeeze your

production costs but never at the expense of quality, safetyor the environment.

Mining and construction is a tough and competitive business.Fortunately, our view on cutting costs is just as hard.

Get your free copy of Success Stories atwww.atlascopco.com/rock

Atlas Copco Rock Drills AB

Fax: +46 8 670 7393

www.atlascopco.com

Committed to your superior productivity.


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LOADING AND HAULAGE IN UNDERGROUND MINING 1

Foreword

2 Foreword by Robert Almqvist, Product Line Manager LHDEquipment, Atlas Copco Rock Drills AB

Talking Technically

3 Matching the Scooptram to the Job

9 Minetruck Designed for Underground Applications

11 Upgraded Minetruck MT2010

13 CARE For Mining

15 Rig Control System for Scooptram Loaders

19 Efficient Underground Loading and Haulage

21 Automation in Mining

23 Service Parts for Scooptram and Minetruck

Case Studies

25 Loading in Low Headroom at Waterval

27 Keeping a Low Profile at Panasqueira

31 Getting the Best For Penoles

35 Scooptram ST14 Earns Top Rating

39 Scooptram Impresses Miners in Both Hemispheres

41 High Speed Haulage at Stawell

43 Revival in the Sudbury Basin

Product Specifications

47 Underground Loaders

87 Underground Electric Loaders

95 Underground Trucks

119 Grade Conversion Graph

120 Conversion Table

Front cover: Atlas Copco Scooptram and Minetruck operating underground.

Scooptram and Boomer are Atlas Copco trademarks. AtlasCopco reserves the right to alter its product specifications atany time. For latest updates contact your local Atlas CopcoCustomer Center or refer to www.atlascopco.com/rock

Contents

Produced by tunnelbuilder ltd for Atlas Copco Rock Drills AB, SE-701 91 rebro, Sweden, tel +46 19 670 -7000, fax - 7393.PublisherUlf [email protected] EditorMike [email protected] Senior Adviser Hans [email protected] Picture and Specifications EditorHanna [email protected] Dubois, Anders Fryseth, Anne Marie Grossi, Casper Swart, Dave Ogilvie, Don Thompson, Elfrieda Tyrer,Erik Svedlund, Fredrik Green, Hugo Dias, Jonas Henrysson, Karl-Erik Niva, Karl-Johan Dahlin, Kjell Fjordell, Lars-Gran Larsson,Lori-Anne Fleming, Mark Smith, Matt Cobbham, Olle Lundkvist, Peter Trimmel, Reg Labelle, Robert Almqvist, Ulrik Algulin,all [email protected] Maurice Jones [email protected]. Adriana Potts, Ulf Sellman

Designed and typeset by ahrt, rebro, SwedenPrinted by Welins Tryckeri AB, rebro, Sweden

Copyright 2007 Atlas Copco Rock Drills AB.

Copies of all Atlas Copco reference editions can be ordered in DVD formatfrom the publisher, address above, or online at www.atlascopco.com/rock.

Reproduction of individual articles only by agreement with the publisher.


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2 LOADING AND HAULAGE IN UNDERGROUND MINING

ForewordSince the introduction of our first railbound pneumatic shovelloader in the 1930s, we have been providing our customers withunderground loading and haulage equipment. In our product

development, our target has always been to improve productiv-ity, reliability, ergonomics, service friendliness, and not the least,safety!

Railbound machines, as the first step of mechanization, improvedproductivity in mines tremendously. However, railbound equip-

ment has limitations in terms of flexibility. This resulted in the

development of rubber-tyred pneumatic LHD loaders, starting

with the T4G in 1956, and followed by the Cavo 310 and 511four-wheel drive versions. These vehicles eliminated the problemof tracklaying, but were still limited in mobility due to their needfor compressed air.

The next milestone was the introduction of the first Scooptram,the ST5. This vehicle was developed by Eddie Wagner, and wasthe first diesel-driven Load Haul Dump loader for underground

mining. Eddies brother Elmer had earlier invented the 4-wheel

drive articulated vehicle in 1949. Scooptram loaders have, sincetheir introduction into the mines in 1963, been recognized for

their flexibility, high productivity and low cost of operation.

The real breakthrough for Scooptram loaders came during the

1970s after the introduction of hydraulic rock drilling. The com-bination of hydraulic drill rigs and LHDs became a flexible andcompetitive package for underground mining operations. Thenewly-invented Robbins raise drill also offered an efficient alter-

native for improving ventilation systems in mines when changingfrom pneumatics to diesel and electro/hydraulic power.

In 2003, for reasons of synergy, we decided to move productionof Scooptram and Minetruck products from Oregon in US toour drill rig manufacturing plant in Orebro in Sweden. We knewwhat had to be achieved and, within a very tight schedule, thenew assembly hall was designed and built, the engineering facil-ity re-established, and the production lines set up and manned.

An aggressive new product development plan was establishedbased on thorough market surveys, interviews of numerousoperators, service people and mine management in the major

mining countries. The first result is the 14 t loader ScooptramST14. With an efficient load sensing hydraulic system, a modernaccurate control system and a cab with Business Class ergo-nomics, it has received acclaim as the most productive loader inits class. It is designed to meet the most stringent requirements

of the international mining and tunnelling industries. Not only

is it fast and comfortable to drive, it is also highly productiveand easy to maintain.

The Rig Control System featured on the Scooptram ST14 is acommon automation platform for nearly every type of machine

produced at Orebro, eliminating hydraulics from the cabin,reducing electrical connections, facilitating fault finding, record-

ing and displaying data, and offering the option of radio remotecontrol. Easy access for quick maintenance is also an importantfeature.

All loaders and trucks in our product range have been upgraded,mainly to improve reliability and serviceability. The most obvi-

ous examples are the Scooptram ST1030 and the MinetruckMT2010 which have been equipped with the new CumminsQSL 9 diesel engine. It is a modern clean burning, fuel efficientengine that meets the US EPA Tier 3 and the European stage 3Aemissions regulations. Also, we have added low profile loaders

to our portfolio, like the ST1030LP and ST1520LP.

Our optimism for the future leads us to publish this book, inwhich we describe our products, their applications, and theirspecifications. We hope the mix of technical papers, case studies,and vehicle descriptions is to your liking, and will help you toselect the right equipment for your application.

Of one thing you can be sure: we will continue to be drivenby innovation and a solid commitment to providing first classservice.

Robert Almqvist

Product Line Manager LHD Equipment


[email protected]


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LHD machines in mines

Mechanization of underground produc-tion and development has led to increas-ing use of LHD equipment, because of

their success in the par ticularly harsh

mining environment. Not only are theirdimensions favourable to underground

operations, but LHDs have also demon-strated capability for climbing steep

gradients, and for moving quickly over

long distances. LHD technology hascontinuously improved productivity

under all mining conditions, from smalland narrow orebodies to the largest of

open stopes, and in low headroom and

difficult entries. In essence, LHDs are

semi-rigid, low profile loaders with

large bucket volumes that give high

mucking capacities in limited spaces.

They are especially good in mining

applications, with their combination of

capacity, manoeuvrability and speed.

Diesel powered LHDs are versatileand flexible, and find a variety of uses in

mining, apart from their normal work

on production and development. They

may be used for road cleaning, materialhaulage, or loading trucks.

When loading between stope and

orepass, the haulage distance is usuallybetween 50 m and 400 m, whereas less

than 100 m tramming is normal when

loading trucks.

All in all, LHDs feature around 50%

higher payloads compared to front endloaders with the same engine size, and

their long wheelbase gives better sta-

bility and higher tramming speeds car-rying a full load.

Dimensions

Regulations for vehicles working under-ground usually focus on minimum wor-king clearances and ventilation require-ments, which will limit the choice of

size of unit and its horsepower setting,and possibly decide between diesel and

electric power. Trends in mine design

are to accommodate the most-productiveequipment possible, because operating

costs have been shown not to be directlyproportional with increased capacity.

Also, the cost of labour is significant, nomatter the location, and this may favourlarger machines. Nevertheless, there arephysical and financial limitations on

the size of openings underground, so

the fit of the machine becomes a majorconsideration.

In mine operations, the clearance

between vehicle and sidewalls, and ope-rator and roof, are critical factors, whichwill help decide the model best-suited

to the conditions. A rule of thumb is

to allow a total of one metre minimum

operating clearance between vehicle andsidewalls. Sometimes, when a mine is

mechanizing using trackless vehicles,

the enhanced productivity may allow

for enlargement of openings. More oftenthan not, the vehicle has to fit the

Matching the Scooptram to the job

Original and bestFor nearly 50 years, Scooptramloaders have been recognized forreliability, power and low cost ofoperation. Since the first LHD wasintroduced into the mines in 1958,development has been continu-ous, resulting in the current rangeof Scooptram loaders, designedto satisfy all production require-ments at low cost/tonne. In eachsucceeding generation, designimprovements are added, build-ing upon established modelstrengths. Now that Scooptram

loaders are built in the AtlasCopco plant at rebro, Sweden,the pool of available engineeringexpertise has grown consider-ably, reflected in recent announ-cements of all-new models suchas the Scooptram ST14 loader.These next generation loadersare being added to the currentrange of basic models plus vari-ants designed to satisfy the moststringent requirements of t heinternational mining and tunnel-ling industries.

Scooptram ST1030 ready for work.


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TALKING TECHNICALLY

existing openings, and the model will

be chosen on the basis of the highest

productivity achievable given these con-straints.

Bucket capacity

Selection of Scooptram bucket size willbe governed by the density of the mate-rial to be moved. Rock may swell by

as much 60% when blasted, and its

loose weight/cu m has to be establishedbefore recommendations can be made

about bucket size. Likewise, abrasivity

of the mineral will affect the choice of

wear parts for the bucket. The bucket

rated capacity will normally be quoted

by reference to heaped capacity, butaverage fil l achieved will depend on

other factors, such as driver expertise,

blasting fragmentation, roadway condi-tion, and route alignment.

Atlas Copco establishes a rated tram-ming capacity for each of its Scooptramloader models, which is the gross recom-mended payload. They then calculate

the standard bucket size, based on mate-rial weighing 2.0 or 2.2 t/cu m. If the

material to be moved is heavier than

this, a smaller bucket may be fitted. Ifthe material is l ighter, a larger bucket

may be recommended to take full ad-

vantage of the rated tramming capacity.Engine, torque converter and transmis-

sion are matched and approved for eachmodel, along with axle and tyre capa-cities. The engineers then consider theoverall quality and strength of their de-sign against the envisaged working cycleand projected life. This will result in a

qualified statement of rated capacity.

Payload should be as close as possibleto the rated tramming capacity for the

selected model, and overloading shouldbe avoided. Consistent overloading,

while apparently attractive, will result

in excessive tyre wear, higher operat-

ing costs, and shorter working life for

the vehicle. Different size buckets areavailable in increments of 0.2 t/cu m to

suit the broken density of the rock to beloaded.

One-pass loading

Optimized one-pass loading is a major

contributor to overall productivity, and

Atlas Copco has devoted much time andresources to perfecting this technique.

These new design features have been

incorporated into the latest models ofScooptram loader, such as: the high-shape,

high-angle bucket; the Z-bar bucket

linkage for higher breakout force; and

a higher power-to-weight ratio, with

fully-integrated drivetrain, for better

tractive effort. As a result, the attack

on the muckpile is a more controlled

event, with power directed to the bucketedge, instead of being wasted in wheel

spinning.

The breakout force in the muckpile isa combination of mechanical force pro-vided by the weight and forward move-ment of the Scooptram and hydraulic

force provided by skilful movement of

the bucket and boom by the operator.

To reduce bucket loading time, powerfulhydraulics are required with both tilt and

lift functions operating simultaneously.These have to react against the load

frame, thereby distributing the stresses

throughout the frame. Better visibility

for the operator allows for more efficientloading, resulting in less stress trans-

ferred to the frame. For consistent one

pass loading under all conditions, joy-

stick operation and sensitive controls

are a basic requirement. For the trip to

the discharge point, the narrow dimen-

sions of the Scooptram loader, and its

85 degree turning angle, ensure thattime saved on loading is not wasted when

Scooptram ST14 side view.


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TALKING TECHNICALLY

tramming. One pass loading, safe tram-

ming, and efficient dumping, turn ingand accelerating, will result in the best

possible cycle time. For loading into aMinetruck, the norm is to ensure that

the truck is filled in 3-4 passes.

Breakout force

As there is no commonly accepted normfor measuring the breakout force of LHDloaders, it is usual to apply the figures

defined for surface loaders. Both SAE

and ISO norms are available for surfaceloaders, and give roughly the same break-out force.

Breakout force is expressed in two

different ways, as hydraulic breakoutforce, and as static vehicle breakout force,which is also called static tipping capac-ity, SAE J732.

The Society of Automotive Engineers(SAE) defines hydraulic breakout forceas the maximum sustained vertical up-

ward force exerted 100 mm (4 in)

behind the tip of the bucket cutting edge,and is achieved through the ability to

lift and/or roll back the bucket about

a pivot point. It is measured with the

pivot point supported, and the vehicleanchored to avoid any movement.

The static vehicle breakout force is

the minimum amount of hydraulic break-

out force that will rotate the vehicle aboutthe front axle, lifting the rear wheels

clear of the ground. It is measured whilethe vehicles brakes are off, and with itstransmission in neutral.

The difference between these two

types of breakout force is important in

assessing the design productivity of thevehicle, because not all of the hydrau-

lic breakout force can be utilized if it

causes the rear wheels to leave the

ground.

Most manufacturers of LHD loadersuse the bucket tilt circuit to maximize

the hydraulic breakout force. However,

the standard does not determine the dis-tance of the measuring point from the

bucket pivot point, so the breakout forcecan be varied with the same loader whenoperating the bucket circuit, simply by

using different types or sizes of bucket.This can result in confusion, so compar-isons should only be made of machineswith similar buckets in which the depthof the cutting edge or bucket volume is

the same.

In a powerful loader making the best

use of its hydraulics, the breakout forceusing the lift circuit should be sufficient

to raise the rear of the machine off the

ground, while the hydraulic breakout

force using the lift circuit with the rear

of the machine anchored should exceedthe force obtained using the bucket tilt

circuit.

Load sensing hydraulics

Whenever a loader attacks a rock pile

underground, a tremendous amount of

power is required to thrust the bucket

deep enough so that it can be filled to

capacity. Wheels spin, buckets get stuckand the vehicle often has to make se-

veral attempts before successfully pene-trating the muck. Sometimes, the driver

has to be content to pull away with onlya partial bucket load.

In the same way, LHDs that have to

tackle steep, uphill gradients need extrapower to maintain sufficient speed to

ensure that the load will reach its desti-nation within the projected cycle time.

The latest Scooptram ST14 is fitted with

a modern Load Sensing Hydraulic Sy-

stem, which is well-proven and reliable.For more information about the this sy-stem, please see page 19 and the article

Efficient Underground Loading andHaulage.

A full bucket is the objective of every trip to the muckpile.


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TALKING TECHNICALLY

Safety and control

Creating a safe and comfortable envi-

ronment for drivers is now, more than

ever, a top priority. The Scooptram

loader driver is side-seated, for bi-direc-tional operation and maximum visibility.Every Scooptram is fitted with an ope-

rators cabin or canopy, certified to

meet cur rent regulations, including

ROPS/FOPS, EC and MSHA. They

feature a comfortable seat with plenty

of legroom, and correct ergonomic posi-tioning, designed to reduce driver fati-

gue and create a much-improved safetyenvironment. The cabins are proofed

against sound and vibration, and wider

windows give the driver improved vis-

ibility, enhanced by well-placed, high-

intensity lights.

Improving driver control is always

high on the list of priorities. Scooptramshave: automatic gear selection which

matches the correct gear to the operat-

ing load; a two-handed electric control

system, which allows the driver to focus

on loading and tramming, rather thanon gear changing; forward, reverse, and

neutral buttons on the hoist and dump

controls; and the SAHR braking system,considered to be the safest available.

Low operating costs

Reducing maintenance cost and time

contributes to a lower cost of ownership

and higher productivity. Atlas Copco

has designed low maintenance into its

Scooptram loaders, with fewer wear

parts, improved durability of spares,

and components that are mutch easier

to maintain.

The trunnion caps retention assem-bly makes pin replacement faster and

easier when changing cylinders and

buckets. The electronically controlled

transverter is fully integrated with the

engine in a matched powertrain that

delivers longer lifespan.

A tapered roller bearing articula-

tion hinge offers more than 10,000 h

service. Hydraulic manifolds replace

piping wherever possible, and hydrau-

lic pumps are mounted above the

transverter for easy access and quickmaintenance.

The economical working life of an

LHD is decided when the graph of totalcosts, including depreciation and main-tenance, rises above an acceptable level.As a machine gets older, its capital costsreduce and its maintenance costs rise.

Selecting the correct model will result

in optimum capital costs, while en-

gineering design and regular servicing

will help control the maintenance costs,resulting in a long working life and a

lower cost/tonne.

Operator first - latest

Scooptram ST14Based on the principle that job satisfac-tion has a significant impact on produc-tivity, in designing the next generation

Scooptram series of loaders, Atlas Copcohas put operator safety, comfort and

working environment first.

The new Scooptram ST14 loader pro-vides excellent visibility from the cab,

due to a combination of large wind-

screens, a clean, flat top to the vehicle,

and a short and low-level rear end. The

driving seat is air-suspended and softer

Efficient LHD operations in the Jacobina Mine in Brazil.


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and more comfortable than in other

LHDs, with the controls located in thearmrests. The drive train design has cre-ated more free space in front of the cab,accommodating a unique, roomy foot-

box into which the driver can stretch

out his legs.

When driving the ST14, the operatoris conscious of a spacious and clean en-vironment in the cab, and the long wheel-base makes for a smooth ride. The ride

control system allows the loaded vehicleto be driven at high speed while still

retaining maximum comfort.

Effective climate control, and the

absence of hydraulic hoses in the cab,

also contribute to a good environment,

both in terms of temperature and air

quality, and to safety.

The ST14 aims to prove the conceptthat an investment in an exceptionally

good working environment is an invest-ment in increased productivity.

Versatile and productive- Scooptram ST710

One of the most versatile 6.5 t LHDs onthe market today, the Scooptram ST710is packed full of productivity enhanc-

ing features. Compared with other 6.5

t loaders, the ST710 wins hands down,with the highest bucket lift and longest

reach. It also makes claim to one of thefastest tramming speeds for loaders in

its class.

The narrow 2.14 m width of the ST710allows it to work in drift sizes down

to 2.9 m-wide x 3.7 m-high. Available

with a choice of two 6-cylinder water-

cooled engines, the 200 hp (149 kW)

Deutz Diesel and optional 210 hp

(157 kW) Detroit Diesel, the versatile

ST710 is a highly productive performer.

Matched with a Minetruck MT2010 andBoomer 281 dri ll rig, the Scooptram

ST710 can provide the centrepiece of anunbeatable team for medium-section

tunnelling.

Productivity with comfort- Scooptram ST1030

The new 10 t-capacity loader from AtlasCopco, the Scooptram ST1030, carries

forward a long legacy of high produc-

tivity in this payload category. Buildingupon the strengths of the popular ST1020,The circles are showing where the trunnion caps are placed.


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TALKING TECHNICALLY

the ST1030 incorporates numerous designimprovements and customer suggestions,including the new ergonomically designedoperators cabin offering reduce fat-

igue and better safety, and easy ser-

viceability of the split-cap pins and

hydraulic system.

With a Cummins QSL 9, Tier 3 diesel

engine rated at 250 hp (186 kW) and

transmission, and mono-stick controlledarticulated hydraulic power steering,

the ST1030 makes driving a pleasure.

Add to this the excellent breakout force,and a 25 km/h tramming speed on the

flat, and the ST1030 becomes one of

the most productive LHDs available forworking in drift sections down to 3.3 m-wide x 3.9 m-high.

Big payload- Scooptram ST1520

Designed for size, strength and ease of

operation, the Scooptram ST1520

achieves the highest productivity for

any loader in its class.

This 15 t-capacity loader provides su-

perb visibility from the ergonomically

designed and safe operators cabin. Equip-ped with a 400 hp (299 kW) 6-cylinder

water-cooled Detroit Diesel engine, itsrugged structure makes it a champion

performer, both in the muck pile and intramming over long distances.

Constructed upon the same prin-

ciples as the ST710 and ST1030, the

ST1520 includes all the innovation and

improvements from these models, ma-

king it an unparalleled production per-

former in drifts down to 4 m-wide x 5 m-high.

Summary

The wealth of experience gained by

Scooptram loader designers over the

last half century is put at the disposal

of the purchaser. This ensures that all

operational considerations are taken

into account in their recommendations

for the correct vehicle for the job.

Dave Ogilvie

[email protected]

The Atlas Copco footbox on Scooptram ST1030.

Scooptram ST1030 in Kvarntorp mine, Sweden .


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TALKING TECHNICALLY

Standard features

The model range covers capacities from20 to 50 metric tonnes, with options fordifferent material densities. All the

Minetruck products can be fitted withAnsul fire suppression, Lincoln auto

lube and Wiggins fast fuel fill, in additionto a comprehensive range of options.

The Minetruck MT2010 is covered in

detail later in this edition, while the threelarger members of its family are de-

scribed below.

All Minetruck versions feature ROPS/FOPS canopy with back protection; auto-matic engine overspeed protection, andreduced heat from braking; electric trans-mission shift control for convenient shif-ting; converter lockup for better power

transfer, less heat and longer componentlife; centralized lubrication to simplifymaintenance; and SAHR brake system

for reliable braking.

The productivity of trucks is measuredby the tonnage carried per km/hour.

The cost/tonne of moving the material

is then derived from this figure.

Minetruck MT431B

The MT431B is a 28.1 t-capacity truck

for large underground operations inmining and construction. Its dump box

can be emptied in 14 seconds. It is mat-ched to Scooptram loaders ST1030 andST14. It is powered by a Detroit Diesel

DDEC Series 60 engine with a rating at2,100 rev/min of 298 kW/400 hp. It has

a Spicer 6000 Series transmission withfull power shift on 4 speed forward andreverse through a single stage Spicer

CL-8000 series torque converter with

lockup to Rock Tough 508 axles. SAHR

braking with fully-enclosed, force-cooledmultiple wet discs at each wheel end

offers long component life and reliable

braking. The operator is side seated in aGrammer seat with retractable seat beltsfor bi-directional dr iving, using two

pilot operated joysticks for steering

and dump control, and is protected by

a canopy that is MSHA-ISO ROPS/

FOPS approved.

The MT 431B has a top speed on thelevel of 24.8 km/h empty and 22.8 km/h

loaded.It has a fuel tank capacity of439 litres, with a fuel consumption at

full load of 35.5 litres/h. It has a height

of 2.74 m to the canopy roof, a width

of 2.795 m, a length of 10.18 m, and aturning angle of 42.5 degrees. It will

operate in galleries of 5.5 m-width withchamfered corners.

Minetruck MT436B

The Minetruck MT436B has a similar

specification to the MT431B, with a widerbody and larger 32.6 t-capacity. The

MT436B has a height of 2.68 m to the

canopy roof, a width of 3.065 m, a lengthof 10.18 m, and a turning angle of 42.5degrees. It will operate in galleries of

4.54 m-width with chamfered corners,and is matched to Scooptram loaders

ST1030 and ST14.

Minetruck MT5010

The high-performance MT5010 truckhas a true 50 t-capacity dump box with

Minetruck designed forunderground applications

Choice of fourmodelsAtlas Copco Minetruck vehiclesare specifically designed for un-derground use, whether to be loa-ded by Scooptram or chute, andfor long haul or short haul. Theyare high powered to cope withthe steep gradients in mines, havelow heights and short turning circ-

les to negotiate underground road-ways, and are extremely robust.They have economical, low emis-sion diesel engines selected fortheir suitability to the rugged mineenvironment.

Minetruck MT5010.


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optimum profile for clean and fast dum-ping offering unparalleled productivity

in demanding underground operations.

It is matched to Scooptram ST1520 for

loading.

Power is provided by a Cummins

QSK19-C650 485 kW/650 hp clean bur-ning diesel engine. The unique power

train includes an upbox and a combinedtransmission and converter which, along

with the engine control system, offerssmooth and precise shifting. The MT5010has all-wheel drive through conventionalfront and rear differentials and Spicer

53R300 series axles with centre-flange

hubs and wheels to match its capacity.

It has an ergonomically-designed, for-ward seating, sound-proofed, air-con-

ditioned cabin in which the operator

also benefits from a functional instru-

mentation layout with monitoring of the

hydraulic and lubrication systems. A rear

view camera improves the operatorsvision when reversing.

Component access is first class, and

the filters are centralized in an easily

reachable area. Fuel tank capacity is

644 litres, with a dieseline consumptionat full load of 57 litres/h. Fuel tank accesscovers are readily removed, and point-

to-point wiring improves testing and

fault location. The dimensions of the

MT5010 are 3.2 m-wide, 3.15 m-high

to the top of the dump box, and 11.22

m-long. It will operate in galleries of5.01 m-width with chamfered corners.

Scooptram loading

The general rule for filling the Minetruckusing a Scooptram is that the loader

should complete the operation in threeor four clean passes. The Scooptram

bucket volume may be changed to achievethis ratio in order to maximize the truckload.

For end loading, the bucket widthshould be 150 mm narrower than the

inside dimension of the truck box, and

for side loading, the top of the bucket

should extend no more than 400-500 mmbelow the box side in the dump position.The bucket lip should reach to the cen-

treline of the box for perfect loading.

Eject-O-Dump buckets are availablefor use where ground conditions do notpermit adequate back height for Scoop-tram side loading. Using this system, the

bucket pin height should be able toclear the box side.

Eject-O-Dump buckets reduce the

Scooptram capacity by 10-15%, and thisshould be taken into account when se-

lecting the most suitable Minetruck.

Kjell [email protected]

Minetruck MT5010 at Ridgeway Australia.


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Main objectives

Atlas Copco first introduced four-wheeldrive mine t rucks in 1960, when the

MT10 was built for use in undergroundmines. In 1985, the MT420 was intro-

duced, and 94 units were sold by 2002.

The MT420B was manufactured in par-allel in 1998-1999, and 16 units were

produced. Its successor, the MT2000,

has added another 94 units to this largefleet. Now, the MT2010 takes the placeof the MT2000.

The design philosophy for the MT2010has been to increase productivity and

decrease operating cost, resulting in a

lower cost/tonne for the customer. It hastherefore been designed to improve ser-viceability and to reach higher levels of

availability and reliability.Many of the changes to the MT2010

are similar to those on the recently up-

graded Scooptram ST1030 loader, whichhas also been the subject of redesigned

electrics. The two vehicles have the samenew instrument panel with built-in datacollection unit. The panel features an

integrated warning system and an enginefault code display. The system also indi-cates when it is time to change the air

filters. The PLC has been moved into

the cabin for better protection from theworking environment.

The MT2010 has been designed withspecial attention to driver comfort, withergonomic seat, extended legroom, andresponsive mono-stick steering, which

requires very little effort, reduces fatigue,and helps productivity.

New engine

The Cummins QSL 9 diesel engine fit-

ted to the MT2010 is clean burning, and

meets the US EPA Tier 3 and the Euro-pean stage 3A emissions regulations.

IncreasedproductivityAtlas Copco recently upgraded thepopular Minetruck MT2000 toMT2010 with a change of engineand redesigned electrical system.Other minor revisions have beenincorporated, and the whole con-cept mine tested under rigorousconditions for 2,500 hours in Tur-key. The customer reported thatthe trial went very well, with goodperformance, easier maintenance,and excellent operator acceptabil-

ity. Absolutely no technical issuesneeded to be addressed, and thegeneral feedback indicated thatthe truck is seen as very powerfuland comfortable to drive.

Minetruck MT2010 in Kvarntorp, Sweden.

Upgraded Minetruck MT2010


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TALKING TECHNICALLY

The QSL 9 was first delivered with the

Scooptram ST1030 for six months. Thereports from the customers were posi-

tive and the engine was selected for theMT2010 as well.

The fully electronically controlled

Cummins QSL 9 has a high-density

power design with an electrical sensor

for air intake restriction. The alternatoris solid mounted to the engine, with a

multi rib belt with spring-operated ten-

sioner. The transmission cooler has beenincorporated into the radiator for bettercooling capacity and easier access, and

the engine benefits from electronic pro-tection for overheat or low oil pressure.Diagnostic software is available.

The Cummins QSL 9 C300 is an

8.9 litre in-line six-cylinder engine thatweighs just 738 kg and is rated as 224

kW/300 hp power output. Its overall di-mensions are smaller than its prede-

cessor in the MT2000.

The engine has a high-pressure com-mon rail fuel system with electronic in-jection and a wastegate turbocharger.

Users can expect a longer working lifedue to the lower piston speed, while the

bypass oil filtration in combination withfull flow will increase bearing and ringlife. All of this adds up to a smootherrunning engine with lower maintenanceand overhaul costs.

Drivetrain and options

The MT2010 has an oversized Clark

5000 series transmission for long life,

and converter lock-up to transmit more

power to the ground with less heat

build-up.

The SAHR brakes are fully enclosed,

force cooled, with multiple wet discs ateach wheel end. Benefits are a 10,000 hlife without adjustment, and increased

vehicle safety from what is the safest

brake in the mining industry.

The tapered roller bearing articula-

tion hinge on the MT2010 also has a

10,000 h life without adjustment.

The Rock Tough axles have a 4,000

h warranty as the best in the industry,

with SAHR brakes as an integral part

of their design. Conventional differen-

tials are standard in both front and rearaxles. Lincoln automatic lubrication and

Ansul fire protection can be fitted, and

the vehicle can be specified with an ejec-tor box.

The Minetruck MT2010 is purpose

matched with the Scooptram 710 and

1030 as efficient loading and hauling

combinations.

Kjell Fjordell

[email protected]

The trial test of the QSL9 engine was conducted in Koza Mine, Turkey. The truck operated successfully for 2500 hours.


15/124


TALKING TECHNICALLY

Exercising CARE

Using CARE For Mining, the vehicle

needs for the whole mine can be evalu-ated. Simulation using a mathematical

model of the proposed system to deal

with stochastic variables is far more ac-curate than the traditional spreadsheet.

Individual vehicles behave indepen-

dently of each other in terms of avail-

ability and shift schedules, but, in real

life, queues and traffic disturbance in-

teract to cause dependence on each

other. Simulation allows the engineers

to evaluate this behaviour over time,

and under different conditions, show-

ing the interaction between various ele-ments and how they affect system per-

formance. Vehicles of different typesand capacities can be inserted into the

CARE simulation, together with severalproduction locations. It will handle bothtruck and loader estimations, and takesdifferent scenarios and varying traffic

conditions into account.

Studies have been undertaken at vari-ous mine locations in order to broaden

the database, and some of the results

are examined in this article.

CARE For Mining simulations are

designed for use in all underground loa-ding and transport situations, and will

supply the mine management with vitalinputs to their equipment purchase deci-sions.

To summarize, the tool will simulateloading and transport of ore and waste

for any hard rock underground mine,

and will determine truck and loader

needs for different scenarios taking intoaccount the effects of traffic disturbance,availability and preventive maintenance.The best setup can be estimated in a

given scenario based on costs, vehicle

types, availability, rock properties, pro-duction plan and shift schedules. In ad-dition, different mine layouts can be

investigated with respect to productivity.

Simulation as a tool

The CARE For Mining simulation tech-

nique is based on trial and error, testinga given scenario for success. A scenariois set up, the simulation is run, the resultis analysed, and then the process is rerunwith new data, if necessary.

Conventional wisdom is to concen-

trate on the problem, not on the data

available. Reality can be simplified. If

an easy model is chosen initially, and

more logic is added when the easy logicgenerates some results, the objective willbe achieved more rationally. Simulation

is simply a mathematical model of areal or proposed process or system, in

which objects behave more like real

life. This is not possible using Excel

calculations because too many input

parameters are not deterministic,

slack time phenomena are hard to assess,traffic congestion is non-linear by nature,and randomness is hard to simulate.

Hence, for complex processes suchas loading and transport logistics withina limited capacity system where parts

interact with each other, simulation is

necessary.

In underground mines, there are al-

ways special considerations, and these

include: how to set up when the last

loading point is a conveyor belt; how toset up loading from a loading bay only,

without any stope or face; how to set uptruck needs only, without any loaders

affecting the result; and how to set up

for chute loading.

Vazante mine study

A simulation of loading and transport

requirements was undertaken at Vazantemine, part of the Votorantim Metals

group, in November, 2006. The purposewas to estimate the vehicle requirementfor replacement of the mine truck and

loader fleet. Capacity simulation of

loading and transport of ore and waste

rock in the mine was undertaken, with-out costs calculations.

Matching the fleetto the jobIn these days of instant cost ana-lysis, it is increasingly difficult todisguise low productivity. The em-phasis on unit costs, in particular,focuses on the performance of themain production fleet. As capitalequipment becomes more reliable,its productivity increases. How-ever, productivity is a function ofutilization, making it essential thatthe fleet strength is closely mat-ched to the job. Numbers and ca-

pacities of trucks and loaders arekey to this, and the Atlas CopcoCARE For Mining simulation toolprovides the mine operator witha reliable means of estimating thisrequirement.

Scooptram ST14 in Kvarntorp, Sweden.

CARE for mining


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TALKING TECHNICALLY

The current situation was set up usingmine data for January to October, and

then adjusted to give results similar to

real life. Because vehicles were report-

edly overloaded in normal operation,

their rated capacity was increased for

the purposes of calculation, and a fill

factor was not used.

The input data from the first simu-

lation was applied to simulate replace-

ment with Atlas Copco loaders and

trucks, using information supplied byAtlas Copco.

The results from the second simula-

tion were then analysed, and equipmentinput data was progressively refined untilthe output data reflected the customers

production needs. Mechanical availabil-ity was used, rather than calendar-based

availability. Production over the periodwas 1,174,062 t using nine trucks of vari-ous designations, for which total hauled,total hours, tonnes/h, and real tonnage

were entered into the simulation.

Conclusions

Operational parameters dictate that themine would need two of the MT5010

trucks to be equipped with teletram

boxes, and only 80% mechanical avail-

ability is proposed for all trucks. Thisresults in a simulation where four

MT5010s are not enough for the requiredproduction, whereas five MT5010s will

fulfil existing production needs, with

some spare time as margin.

Three loaders are enough, because

idle time is available for them to in-

crease production a little.

The simulation results are estima-

tions only, as a guide to choosing the

right equipment. The results are based

on input data given from the mine.

Acknowledgements

Atlas Copco is grateful to Votorantim

for permission to publish the above

article, which was extracted f rom a

report prepared by consultants Onnerlov

of Mal, Sweden on 21st November, 2006.

Robert [email protected]

62

51

45

41

39

34

43

LP4

LP4

LP4

LP4

LP3

LP4

LP4

978687625203422

32

5411347

65

58101

19

45

Mine layout, according to simplified picture to the left.

Production

Total production (ore) 820.000 tonnes

Total production (waste),508 880 tonnes

Truck fleet, MT5010

Average availability 87%

Box fill factor 92%

Shift schedule

2 x 12 hour shifts, 7 days per week, 52 weeks/year

Effective time in truck approximate 10 hours/shift

Others

Only truck need/capacities are simulated. In the

simulation it is estimated that there will always be oreat the loading bays, i.e. production and LHDs work

flawless.

Dump

Simplified mine layout.

Vehicles Quantity Availability Utilization Capacity(t)

3xST1520 80 65 15

3xMT5010 80 65 50

2xMT5010

teletram 80 65 42.5

Vehicles Totalhauled

Totalhours

Tonne/hour

MT5010_2 312 630 3 698 84.55

MT5010_3 297 229 3 674 80.9

MT5010_4 255 373 3 692 69.17

MT5010_5 255 405 3 709 68.85

MT5010_6 288 235 3 685 78.23

Total 1 408 872 27 391 381.7

One of the simulation set-ups.

Result showing the number of trucks needed.


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TALKING TECHNICALLY

Common automationplatform

Rig Control System (RCS), which is

based on standard PC-computer tech-

nology, is the automation platform for

Atlas Copco equipment.

CAN-bus technology provides the

backbone of RCS. This system is f lexi-

ble and easily expandable, allowing newunits to be added anywhere along the

data bus, without adding another cable.The electronic modules are all developedfor purpose, and are ruggedized and pro-tected from external magnetic and elec-tric influences.

The third generation of RCS has takena quantum leap forward with respect tologging capabilities, serviceability and

machine accuracy. The flexibility of thesystem can be adapted and configured

for all different types of products. Cus-tomers can start at a low level of auto-

mation and, as their requirements change,can upgrade. New functionality can be

added, without major rebuilding of the

machine.

RCS benefits

RCS is the Atlas Copco CMT electroniccontrol system platform. It offers increa-sed serviceability, an improved manma-chine interface with options for easy up-

grades such as to Radio Remote ControlRRC, and comprehensive logging of ma-chine functions. Data is easily collectedand transferred using a USB memory

stick as standard, or other retrieval meansas required.

With RCS, it has become much easier

to get information from the machine forservicing and diagnostics, all of which

is logged and displayed in clear text on

the cabin screen. All of this informationis displayed in one place, and there are

no hydraulics inside the cabin, redu-cing noise levels considerably. All parts

of the control system are strategically

placed to make replacement easy.

Screen display

RCS facilitates improved operator ergo-nomics, clearing the cabin of gauges andinstruments, creating more room and bet-ter visibility.

In the main menu, the operator canchange the screen display to one of a

selection of languages in seconds, allo-wing engineers and operators of severalnationalities to operate and service the

machine without ambiguity. All menus

are self-explanatory, and the screen sym-bols are easily recognizable, so there isno need to interpret the information.

There are several access levels to RCSto prevent accidental or unauthorized

changing of parameters and settings.

These are restricted at the first level tothe operator, then to the local service

Rig Control System forScooptram loaders

Quantum leapThe introduction of the well-provenAtlas Copco Rig Control SystemRCS to Scooptram loaders hasbrought seamless integration withthe drivetrain components. At thesame time, joysticks in armrests,and easy-to-read multifunctioncolour displays on a single screen,have transformed the operatorslife. The same screen allows main-

tenance engineers to check sta-tus on modules and I/O ports, spe-eding fault detection and remedy.With RCS, soft stopped steeringreduces vibration, and boom andbucket movements are better con-trolled, all contributing to lessstress on operator and machine. Areduced number of electrical con-nection points, richer functional-ity, and component commonalitywith other Atlas Copco machinesall add lustre to the performanceof the new generation Scooptramloaders with RCS.

The Scooptram ST14 proves its superior performance in the muck pile.


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TALKING TECHNICALLY

staff, and at the third level to Atlas Copcoservice engineers. As a result, nuisancesite visits to restore settings are elimi-

nated, while fault finding and correctionis vastly improved. The RCS screen pro-vides instantaneous monitoring of ope-rational condition for items such as

torque, intercooler temperature, fuel con-sumption, and engine status. The digitaldashboard shows warnings and stops

on screen, and is completely integrated

with the RCS system. If the icon has a

green background, there is no error; if

yellow, there is a minor error such as

blocked filter; if red, there is a major

error such as low oil pressure, and the

machine is automatically shut down. A

self-diagnostic system makes fault find-ing easy, indicating if there is a modulefailure, and where the problem lies.

RCS for Scooptram

The new generation Scooptram loadersfrom Atlas Copco are assembled on an

RCS platform, which makes them easier

to build and maintain. With all-elec-tronic control, they are automation ready,with much richer functionality and betterergonomy.

It is easier to add options, and all ma-chines are ready for RRC Radio RemoteControl as standard. Previously, addingRRC to a machine required the fitting

of a heavy electro-hydraulic manifold

block to which pilot hoses to the con-

trolled functions had to be connected.

Then the RRC machine unit had to be

installed, and the connections to themanifold block and machine electrical

AHOLMBERG2007

PC-card

CCI module AP module Resolver module I/O module

RCS - a common automation platform.

Default screen.

Bucket count Load Fuel Level

Errors and

warnings

GearRide control

Engine status

Engine

hours


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TALKING TECHNICALLY

system had to be interfaced. Thanks to

RCS, the current RRC installation is

a small MU that fits beneath the seat.

Connect power, CAN and antenna, andit is ready for operation!

Other benefits accrue, such as steer-

ing interlock, redundant design, and newaccess control, all of which make for

greater safety. Likewise, load weighing,soft stops, logging and services inter-

face contribute to functionality.

The first generation of LHDs has me-chanical control linkages. Second gen-

eration has pilot hydraulic controls and

valves, electronic PLC and extra elec-

tronic valves for Radio Remote Control.The current third generation has RCS

architecture, CAN-bus based distribu-

ted control system, and electronicallycontrolled valves replacing the pilot hy-draulics.

As a result, the number of electrical

connection points has decreased by twothirds, reducing the potential for break-down, and making fault detection easier.There is also an interactive user inter-

face, and a common RCS platform withdrill rigs and other Atlas Copco surfaceand underground equipment. Hardwareand software is developed and main-

tained by Atlas Copco AutomationDepartment in Orebro, Sweden.

Current generation

The RCS prototype Scooptram ST1010C was field-tested at a Canadian mine

for 4,400 hours during 2003-2004. Theexperience has been absorbed into the

design of the latest model, the ScooptramST14 launched in 2006.

The ST14 is joystick controlled froma panel in the armrest. The left joysticksteers right and left, with a soft stop.

A steering interlock operates when the

door is open, or the armrest is not in po-sition. The right joystick controls boomand bucket for hoist and dump.

The transmission selects gears in twomajor modes: automatic, in which the

operator chooses direction and range with

dedicated buttons; and semi-automaticin which the operator moves gear rangesup and down as required. There is a ma-nual mode, which is used solely for veri-fication testing. There are brake and

throttle pedals set into the unique foot-

box, developed for this purpose. Logs

are recorded for vehicle statistics over

its entire life. The event log covers the

last 500 events, such as errors, warnings,and restarts. The maintenance log showsessential pressures and temperatures

when limits are exceeded since the lastpower on. Load weighing is integrated

using hydraulic hoist pressures, and theautomatic counting scheme accumulatesloads by counting buckets. The accu-

racy is +/-500 kg.

IREDESIn order to facilitate use of different equip-ment from different producers in the sameorganization, Atlas Copco, together with

other major machine manufacturers, mi-ning and construction companies and

third party suppliers, has established a

standard for data exchange between

rock excavation equipment and users

computer systems. This International

Rock Excavation Equipment Data Ex-

change Standard, or IREDES, is the

common language in data exchange formining and tunnelling, and the current

range of Atlas Copco equipment has beenadapted to IREDES.

The Scooptram ST14, for instance,

exports production data logs in IREDESXML format.

Ulrik [email protected]

OU Operator Unit

Hamess BeltAntenna

Beacon-Red Strobe Flash Light

MU Machine Unit

Hydraulic Interface

Operator working with the Scooptram RRC.


20/124

We understand what youre after

Committed to your superior productivity


Fax: +46 19 670 7393

www.atlascopco.com

Working with Atlas Copco means working with highlyproductive rock drilling solutions. It also means sharing acommon cost-cutting challenge. Like you, we are alwayslooking for new and effective ways to squeeze your production

costs but never at the expense of quality, safety or theenvironment.

Mining and construction is a tough and competitive business.Fortunately, we understand what youre after.

Get your free copy of Success Stories atwww.atlascopco.com/rock


21/124


TALKING TECHNICALLY

Key sourceWhenever a loader attacks a rock pile

underground, a tremendous amount of

power is required to thrust the bucket

deep enough so that it can be filled to

capacity. Wheels spin, buckets get stuck,and the vehicle often has to make severalattempts before successfully penetrat-

ing the muck. Sometimes, the driver hasto be content to pull away with only a

partial bucket load.

In the same way, LHDs that have to

tackle steep, uphill gradients need extrapower to maintain sufficient traction toensure that the load will reach its desti-nation within the projected cycle time.

The key source of power for thrust,

bucket movement and traction does notlie in the size of the diesel engine, but

in the hydraulic pumping system that

distributes and controls the flow of hy-

draulic oil. This is where the power for

all these critical functions is generated,and where power losses can occur. Cur-

rently, there are two systems available.These are the Open Centre and Load

Sensing Hydraulic Systems, discussed

below.

Open Centre HydraulicSystem

With the Open Centre Hydraulic Sy-

stem, the pump constantly delivers a

flow that is proportional to the speed

of the engine. When no function is acti-vated, the oil flows through the open

centre in the valve spools, and is re-turned to the hydraulic tank.

When a function is activated, the

open centre starts to close, which causesthe pressure to rise. At the same time,

the passage to the cylinder begins to

open. The more the spool shifts, the

more the open centre closes, and the

more the pressure is increased. When

the pressure is higher than the cylinder

pressure, the cylinder begins to move,

but oil that is not directed to the cylin-

der is returned to the tank at a pressuredrop, which, in turn, creates heat.

When the spool has been fully shift-ed, the open centre is closed, and the

entire flow goes to the cylinder.

If the load is higher than the maxi-

mum system pressure, the oil goes via

the main relief valve back to the tank

with a maximum pressure drop, which

creates a great deal of heat.

Load Sensing HydraulicSystem

The Load Sensing Hydraulic System,

on the other hand, is a modern, well-

proven and reliable system. It was origi-nally introduced for surface loaders,

but is now available on the latest under-ground loader from Atlas Copco, the

Scooptram ST14, thoroughly tested at

the Kristineberg Mine in Sweden.

Contrary to the Open Centre Hydra-ulic System, the Load Sensing HydraulicSystem on the ST14 has two variable

pumps working together. This providesexactly the right amount of flow and

Efficient underground loadingand haulage

Load sensinghydraulicsPowerful Scooptrams are vital toefficiency in underground loadingand haulage. The objective hasalways been to provide a vehiclethat can be relied on to deliverprecisely the right amount of po-wer at exactly the right moment.This has been little more than a

dream, until the introduction ofthe Load Sensing Hydraulic Sy-stem driven by a variable displace-ment pump. This is replacing thetraditional Open Centre Hydra-ulic System driven by a fixed dis-placement pump, that has servedmany years as the industry stan-dard. Load Sensing HydraulicSystem is a central feature on thelatest Atlas Copco ScooptramST14.

Scooptram ST14 loading at the face.


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TALKING TECHNICALLY

pressure at any one time, distributing

the power wherever and whenever it isneeded.

As the system is activated only whenmoving the control stick, only a mini-

mum of pumping power is lost, therebyreducing fuel consumption. Further-

more, the hydraulic system is faster,

which means shorter working cycle

times and higher productivity, and givesthe operator better control of the load,

resulting in a smoother, more comfort-

able ride.

The spools in the Load Sensing Hy-draulic System are closed centre,

which means that when no function

is activated, no oil flows through thesystem. The pump strokes back to zero

flow, and maintains only a low standbypressure. As soon as a function is ac-

tivated, a pressure signal from the

cylinder port is fed back to the pump,

which then regulates to a pressure leveljust above the highest load.

This means that the pump only de-

livers the flow that is needed at the re-

quired pressure level, and that no oil is

throttled back to the tank, creating heat.

If the load is higher than maximum sy-stem pressure, the pump strokes back

and holds the maximum pressure at

zero flow, again saving energy.

The capabilities of the Load SensingHydraulic System enable the use of a

stiffer converter with a higher degree

of efficiency that transfers more of the

power to the driving wheels, and redu-

ces the amount of heat loss. This resultsin a higher speed on grade for the Scoop-tram ST14, and maximum utilization ofthe installed diesel power. This results

in improved performance, minimum

power losses and lower overall fuel

consumption.

Power losses

Small movements under high pressure

in conventional hydraulic systems al-

ways lead to substantial power losses,and the use of the bucket is a good ex-

ample. It is common practice to move

the bucket slightly, to make it easier to

penetrate the muck pile.

With the Open Centre Hydraulic

System, a large amount of thrusting

power is lost each time the hydraulic oilis activated and directed to the bucket-

moving cylinders, reducing the amountof power retained for traction. With

the modern Load Sensing Hydraulic

System, more than enough power is

retained for both bucket movements andtraction, and the traction power drops

only marginally with each small bucketmovement.

The tests carried out with the Scoop-tram ST14 prove the point. The extra

wheel spin caused by the increased

amount of available power was easily

compensated. By easing up on the

throttle, and attacking the muck pile

at lower revs, the operators found they

could get excellent traction, and save

fuel at the same time.To summarize, the search for in-

creased efficiency in underground load-ing and hauling operations is satisfied

by a vehicle that can deliver the exact

amount of pressure and flow required

for each function. Load Sensing Hy-

draulic Systems in underground equip-

ment such as the Scooptram ST14 are amilestone for Atlas Copco, and a majorstep forward for the industry.

Jonas [email protected]

Pressure

Steering

cylinders

Q pump Max Q pump

Pressure

Savings

Power ConsumptionTramming situation, steering

Steering

cylinders

Open Centre Hydraulic System Load Sensing Hydraulic System ST14

Losses

Losses

Flow Flow

Flow

Pressure

Dump

cylinder

Q pump

Losses Savings

Open Centre Hydraulic System

Power ConsumptionMucking situation, dumping only

Dump

cylinder

Pressure

Flow

Load Sensing Hydraulic System ST14Losses

Pressure

Dump

cylinder

Q pump

Hoist

cylinders

Dump

cylinder

Losses

Losses

Pressure

Savings

Open Centre Hydraulic System Load Sensing Hydraulic System ST14

Power ConsumptionCombined situation, hoist and dump

Hoist

cylinders

Flow Flow

Max Q pump

Max Q pump

In an open centre sys tem, the hydraulic flow (the horizontal axis) is determined by theengine speed (revs) . Consequently, a large amount of unused oil is pumped through thesystem unnecessarily, with corresponding power losses and heat build-up. In a loadsensing system, the hydraulic flow is determined by the actual demand, and the pump onlydelivers the required flow at the required pressure level. No oil is t hrottled back to the t ank,

to create heat and power losses. In both sys tems, the hydraulic pressure (t he vert ical axis)is determined by the actual pressure requirement. By choosing the Load Sensing HydraulicSystem f or the Scooptram ST14, the speed on grade has been increased by up to 14%.During mucking, it is possible to move the bucket with minimal losses of traction force.


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TALKING TECHNICALLY

Natural choice

Underground mining operations with

production processes that are exceptio-nally deep, unusually difficult to access,or extremely hazardous are typical en-

vironments that make automation and

self-operating equipment a natural

choice.

Mining companies currently invest

in automated equipment as a means of

increasing safety, reducing manual re-

petitive work, and increasing overall effi-ciency and productivity.

As one of the worlds leading suppli-ers, Atlas Copco has been instrumentalin developing much of the automation

technology that is available for the mo-dern mining industry. This includes

everything from computerized control

and guidance systems on large under-

ground drill rigs and loaders, to remotecontrol and satellite hole navigation sy-stems on surface crawler rigs.

The aims of such innovations are toconsistently reduce human exposure to

the harsh and dangerous environment

of underground mining and at the same

time increasing efficiency and equip-ment utilization.

Scooptram ST14

The recently launched Atlas Copco

Scooptram ST14 is a typical example.

Vehicles were tested at Bolidens Kris-

tineberg Mine in Sweden, and at IncosStobie Mine in Canada. Other units arebeing delivered to mines in Sweden,

Canada, Portugal, Chile and Russia. This

new loader design reduces the physicalstrain on the operator by making better

use of available power. The bucket pen-etrates the muckpile easier and quicker,and is filled to capacity at every attempt.This increases the number of loads per

shift, with corresponding improvements

in productivity.These productivity and safety ben-

efits are derived from applying the

companys RCS (Rig Control System)and ABC (Advanced Boom Control)

systems witch are already installed on

most of its Rocket Boomer, Simba and

Boltec underground and rigs.

Rig Control System

The ABC system offers three modes:

ABC Basic, Regular or Total. These cor-respond to manual, semi-automatic andfully automatic operation. ABC Total is

Automation in mining

Key roleThe mining industry continues toexperience unprecedented growthas global demands for mineralsand metals remain at record lev-els. Automation is playing a keyrole in the production processand paving the way for futuremining ventures.

Scooptram ST14 with RCS makes better use of available power.

Automation Systems

Mine automation

Increasingp

rocess

integration

Increasing business understanding

Equipm. automation

Automation

development


24/124


TALKING TECHNICALLY

the mode that is now gaining the most

ground, offering accurate and precise

hole collaring, and faster drill and blastwork cycles. Developments such as these

are designed to keep efficiency high andcosts low, so that miners can meet the

future challenges of the industry with

confidence.

As most of the tonnage in tomorrowsworld will be extracted using mecha-

nized equipment, automation makes per-fect sense. But more importantly, it is

getting harder and harder to find new

deposits. When they are found, they aregenerally more difficult and more ex-

pensive to mine than before. The new

mines are often located in remote areas,which are not the most attractive for re-cruiting the best-qualified people. To

mine these deposits profitably, automa-tion will not just be an option, it will bea necessity.

Centre of excellence

When the LKAB-owned mines of

Kiruna in northern Sweden became

mechanized in the 1980s they worked

in close co-operation with Atlas Copco

to develop drill rigs and systems thatcould be controlled at a safe distance

from the mining area. These rigs now

also run during night shifts in automaticmode, entirely without supervision. To-day, rebro in the heartland of Swedenis the centre for Atlas Copco research

and development in this field.

The region has a long tradition of

mining, and it was in rebro that AtlasCopco developed its fi rst Rig Control

System (RCS) in 1996. Since then it

has become the standard for drill rigapplications and the platform for all

subsequent automation innovations by

Atlas Copco.

The PC-based RCS platform, and itsassociated modules, considerably redu-

ce the wear and tear to which miningequipment and personnel are normally

subjected. They make operations fasterand lighter, and make the equipment

easier to handle and maintain.

Much of the communication with

todays rigs is handled through the In-ternet, satellite and telephone, taking

production planning and fault-finding

to a higher level.

Automation in action

Other examples of progress from auto-

mation are automatic bit changers and

automatic tunnel profiling systems.

Measure While Drilling MWD, a sy-stem for the logging of rock strata charac-teristics using the rock drill as a sensor

while drilling the blast holes, is also a

product of automation. Using MWD, thelogged data is transferred to a PC for

further analysis and interpretation. Theresultant data gives a prediction of the

geology ahead of the face, which is in-

valuable when drilling in mixed strata.The focus is increasingly on the use

of technology to preview reality. For ex-ample, it would be hugely advantageousto show the loader operator what the

muck pile looks like before he drives

in, to show the driller what the orebodylooks like before he sets up the rig,

and to show the blaster what the hole

looks like inside before he commences

charging.

LHD automation applications cur-

rently are in the whole production cycle- from teleremote mucking, autonomous

tramming to dump site, auto dumping

and then return autonomously to the

drawpoint for the next loading cycle.

There are also trucking applications

where the trucks are loaded by LHDs orby chutes and then tram autonomously

to the dump site, dump the load and

tram back to loading area. Productivityimprovements, as well as maintenancesavings, are becoming real through allthese various projects mentioned above.

Automated systems provide real-

time information to the management

and supervisors of these mines, not to

mention the operator of the system. Thisis for accurate planning, scheduling andmeasuring the process.

Atlas Copco has learned that, wher-

ever mining and construction activities

may be located, we must continually

strive to make improvements, and we

must never stop trying to increase effi-

ciency for our customers.

- Automation is the key.

Casper [email protected]

Atlas Copco automation products in use.


25/124


TALKING TECHNICALLY

Aftermarket

Aftermarket Marketing Department is

responsible for spare parts policy. The

characteristics of the part greatly affectthe way the spare part level is set. If a

part assembly module includes any wear

parts or consumables that need to be

changed within a regular time interval,

these parts are generally also sold looseor in a kit. If a part is highly advanced

technologically, or has tight tolerances

that may complicate the service or re-

pair, it is generally sold as a complete

functioning unit.

Our spare parts are easy to disassembleand assemble on the machine at site,

without needing to send the vehicle

to the workshop. Thought is given to

whether special tools are needed in

order to properly carry out the service

or repair.

Aftermarket publishes a range of

brochures and a handbook covering

its activities.

One service- one partnumber protocol

Customers gain many advantages by

using parts kits instead of ordering in-

dividual parts and tools separately. Notonly do the kits contain everything ne-

eded for a service, rebuild or overhaul

but they will also save time when carry-ing out the work. Instead of searching forparts, the customer only has to open up

the kit box to find everything required

for servicing his machine. The kits arebased on the parts needed for each

specific job, to meet the service interval

stated in our maintenance manuals.

Our parts kits feature: selected qualityparts and tools for servicing and over-

hauling machines; a solid box containerfor secure shipping and handling at the

job site; one part number, under the one-service-one part number protocol; and

simplified service requirements.

The advantages of using genuine AtlasCopco parts kits are: machine products

are maintained to factory specifications,thus optimizing economic production;

easier order handling and logistics; andthe price is most competitive comparedto buying individual items.

Preventive maintenance

Preventive Maintenance Kits are avai-

lable for Scooptram and Minetruck,

and are based on factory recommenda-

tions for servicing according to engine

or operational hours. PM Kits dependon model of product, and descriptions

Service parts for Scooptramand Minetruck

Spare parts policyThe aim of Atlas Copco serviceparts policy is to promote AtlasCopco Genuine Parts using a OneService - One Part Number proto-col. Our general guidelines recom-mend what parts should be con-sidered for customers stock, andour service kits include all neces-sary parts and tools for the job.All parts needed for our products,

and originally installed at ourfactory, have gone through ourresearch and development pro-cess, with the emphasis on con-sistent quality. Most important toequipment owners and operatorsis the fact that only Atlas CopcoGenuine Parts are covered byAtlas Copco warranty.

Preventive Maintenance Kits for Scooptram and Minetruck.

AtlasCopcoA

ftermarketpr

oducts

Overhaulkits

COP3038

-Onepartnumbe

rfor easierorder

handling

andlogistics.

-Thekitsalsoin

cludetheoverhau

linginstruc-

tionsandsparepar

tslistwhichyoun

eed

foroverhaulingC

OP3038.

-Thepriceismos

tcompetitivecom

paredto

buyingindividual

items.

Mainf

eatures

-Thesekitsconta

inallpartsneede

dformaking

serviceandoverh

aulofyourrock

drill,

COP3038asper

factoryrecomme

ndation.

-Withthesekitsy

ouwillbringyou

rrockdrill

backtofactory

specifications,

andoptimize

yourproductioni

nan economicalw

ay.

-Thepartsareco

ntainedinasolid

woodenbox,

forshippingand

handlingatthejo

bsite.

-All the partsneededforpreventive maintenance servicecontained in one s olid box forshipping andhandling at the job site.

-O ne part numberperservice interval foreasierorderhandling and logistics.

Mainfeatures

- These kitscontain allpartsneeded forpreventive maintenance service based onengine hoursasperfactory recommendation.

-Wi th these kits you will maintain yourmachineasperfactory recommendatio n andoptimize yourproduction in an economicalway.

-The price ismost competitive comparedtobuying individual items

Atlas Copco Aftermarket products

Preventive maintenance kits for ST1030

PreventiveMaintenanceKits

OneServiceOneNumber

ScooptramandMinetruckTM


26/124


TALKING TECHNICALLY

follow industry terminology, such as:

service kit; repair kit; overhaul kit; stan-

dard tool kit; and special tool kit. Eachkit includes all parts that should be re-

placed during the service, repair or over-haul. Depending on the complexity of

the specific maintenance job, instruc-

tion manuals are supplied with the kit.

Preventive Maintenance Kits contents

meet the needs of servicing a product

to meet expected l ife cycle and cost,

compared to the price of replacement.

The kit contents are based upon rec-ommendations from the supplier of the

product and/or Atlas Copco, according

to experience with similar products,

working conditions and environment.

Loader Remote Control

The latest generation of Atlas Copco

Scooptram loaders are ready prepared

to accept Radio Remote Control, RRC.

This is a line-of-sight application that

enables safer and more effective opera-tion in unstable mine stopes. ScooptramRRC gives the operator control of his ma-chine while keeping at a safe distance.

The machine unit and the operator unitsupplied by Atlas Copco have been de-

signed to ensure full interaction with theScooptram. They are lightweight, andhave a long communication range and

long operating time. The system is mo-nitored to detect errors, and there are

several safety features.

Peter [email protected]

Scooptram configured with RRC kit.

Scooptram configured with RRC kit

Scooptram Model Scooptram RRC Kit Hydraulic RRCInstallation kit

Comment

ST2G 5580 0088 00 5575 4856 00 To be verified before order

ST3.5 5580 0083 35 4 different options To be verified before order

ST710 Canopy 5580 0100 18 5572 7585 00

ST710 Cab 5580 0100 97 5572 7585 00

ST1020/ST1030 5580 0085 83 5575 3984 00

ST8B 5580 0084 98 5574 4982 00 To be verified before order

ST1520 5580 0082 43 5575 4616 00


27/124


Thin seam, high output

Waterval Mine is near Rustenburg, about150 km northwest of Johannesburg. It is one

of Anglo Platinums newest mines, and will

be making its contribution to the groups

target by excavating 3.2 million t/year in an

orebody just 0.6 m-thick and on a decline of

nine degrees.

Despite the low seam and restricted mi-

ning space, Anglo Platinum was convinced

that it could tackle the task successfully,

and opted for the room and pillar method

with ramp access, together with mechanized

equipment.

The mine design meant that the roomswould be extremely conned, with a height

of 1.8-2.0 m. This, in turn, meant that head-

ings would have to be as low as possible,

and the equipment extremely compact.

Anglo Platinum also insisted that quan-

tum improvements be made at the mine in

three priority areas: safety, production and

productivity, in that order.

Potential suppliers were assessed by Wa-

terval engineers. Atlas Copco was the only

company able to provide a total solution

around the three key mining tools needed:loader, drill rig, and bolting rig. These needed

to be low prole, compact and techncally

advanced, specially designed for low seam

work and exacting environments.

In addition, Atlas Copco agreed to act as

a cooperation partner in all aspects of the

rock excavation process, providing opera-

tor training, spare parts supply and serviceand maintenance.

Purpose matched package

The equipment trio comprised the Atlas

Copco Scooptram ST600LP loader, the

Rocket Boomer S1L drill rig, and the Boltec

SL bolting rig. The units were progressively

delivered to Waterval, until there were 23

Scooptram ST600LP loaders, 15 Rocket

Boomer rigs, and six Boltec units at the

site.

The Scooptram ST600LP, also known asthe Ratel, is a compact LHD with a height

of around 1.5 m. It has a 6 t loading capaci-

ty, and is equipped with a special bucket for

low height work. It is powered by a clean

burning 136 kW Deutz diesel engine.

The Rocket Boomer S1L has well-proven,

heavy duty Atlas Copco components such

as the COP 1838 rock drill, BUT 28 boom,

and BMH 2837 feed.

The Boltec SL is a high production, semi-

mechanized rock bolting rig with an electri-

cal remote control system. Apart from stan-dard rockbolt installation, it is also equipped

Atlas Copco Scooptram ST600LP

at work in the Waterval stopes.

Loading in low headroom atWaterval

Boosting productionThe Anglo Platinum Group of SouthAfrica, the worlds leading platinumproducer, has completed an ambi-tious plan to boost its annual outputby 75% from 2.2 million ounces to3.5 million ounces by the year 2006.This tough target would have beena daunting prospect for most miningcompanies, especially in conditions atits Waterval mine, where headroomseldom exceeds 2.0 m. However,

Anglo Platinum, which accounts formore than half of the total platinumproduced in South Africa, has veryextensive experience of low seamoperations. This experience led thecompany to Atlas Copco, who sup-plied a complete equipment packageto Watervals specification to meet allof its low headroom loading, drilling,and rock bolting needs.

RUSTENBURG, SOUTH AFRICA


28/124

LOADING IN LOW HEADROOM AT WATERVAL


to perform long hole drilling for anchor and

cable bolting. The Boltec SL uses the same

carrier as the Rocket Boomer S1L, bringing

advantages of commonality.The equipment complement for each min-

ing section is one Rocket Boomer, one Boltec,

and two Scooptram ST600LP loaders.

Production Drilling

The layout at Waterval is divided into 12 sec-

tions with nine panels or stopes. Each panel

averages 12 m-wide x 1.8 m-high, with pil-

lars of approximately 6 m x 6 m. The dril-

lers work three 8 h shifts per day, six days a

week and their target per section is 23,000

t/month. That translates to 200 t per panel,

or two panels per shift. Some 68-74 x 3.4 m-

long holes are required in each panel, taking

around 2.5 h to drill. Three 77 mm holes

form the cut, and the main round is drilled

using Atlas Copco Secoroc model 27 R32

43-45 mm bits.

Ramps from the surface provide the ac-

cess for men, machines and supplies, and

also accommodate conveyor belts for trans-

porting the ore out of the mine. The mine

expects each Rocket Boomer rig to yield

around 200,000 t/year. For rockbolting, 1.6 m-long Swellex bolts

are used, in a standard bolting pattern of 1.5 m

x 1.2-1.5 m. The Boltec SL is equipped with

Secoroc Magnum SR28 Tapered Speedrods,

with 38 mm model -27-67 bits for Swellex

installation. The tramming height of the Bol-

tec SL is just 1.30 m, with ground clearance

of 0.26 m. It is equipped with a COP1028HB

rock drill, and can insert a Swellex bolt of

length up to 1.6 m in roof height of 1.8 m.

With so many available faces in close

proximity to each other in the room and pillar

layout, utilization is a key factor for main-

taining a high level of productivity and ef-

ciency. The required utilization for the drill

rigs ranges from 50 -75%, and availability

is about 90%.

Low height loading

The Scooptram ST600LP is an extremelyrobust loader designed specically for de-

manding thin seam applications where the

roof heights are as low as 1.8 m. For visibi-

lity on the far side of the machine, video ca-

meras point to front and rear, displaying the

views on a screen in the drivers cab.

Loading from the different rooms is a

crucial part of the operation, and the spe-

cially designed E-O-D (Eject-O-Dump) 6 t-

capacity bucket on the Scooptram ST600LP

makes low height work easy. Using the

E-O-D bucket, the rock is pushed out by apush plate onto feeders that transfer it to the

conveyor system for transportation to the sur-

face. The Scooptram loaders are refuelled

underground and generally drive up to the

surface for maintenance.

At Waterval, Anglo Platinum gives top

priority to dilution and utilization. The

amount of rock waste must be kept to an

absolute minimum, and the fact that this can

be achieved with mechanized equipment in

such a low, at seam is seen as a major ac-

hievement.

To ensure high availability of the equip-ment, Anglo Platinum and Atlas Copco have

entered into full-service contracts that pro-

vide for 24 h service and maintenance. It

makes good business sense for the mine to

have a service contract manned by specia-

lists with the technical know-how and skills

for optimal maintenance.

Acknowledgements

Atlas Copco is grateful to the management

at Waterval for their kind assistance in re-vision of this article.

Rocket Boomer S1L working in

low headroom at Waterval.

Room and pillar layout at Waterval

where the Scooptram ST600LP works

in as low as 1.8 m headroom.

AtlasCopcoRockDrillsAB,2001


29/124


Barroca Grande: home to the

worlds largest tungsten mine.Introduction

The Panasqueira mine is located at BarrocaGrande in a mountainous region of Portugal,300 km northeast of the capital city of

Lisbon, and 200 km southeast of the port cityof Porto.

The mining concession lies in moderatelyrugged, pine and eucalyptus covered hills

and valleys, with elevations ranging from

350 m above sea level in the southeast to

a peak of 1,083 m above sea level in the

northwestern corner.The concession area is an irregular shape

trending northwest-southeast, and is approx-imately 7.5 km-long. It is 1.5 km-wide at thesoutheastern end, and 5.0 km-wide at the

northwestern end, where the mine workingsand mill facilities are located.

The geology of the region is character-

ized by stacked quartz veins that lead into

mineralized wolfram-bearing schist. The

mineralized zone has dimensions of approxi-mately 2,500 m in length, varying in width

from 400 m to 2,200 m, and continues to atleast 500 m in depth.

Production levels

Access to the mines main levels is by a 2.5

m x 2.8 m decline from surface, with a gra-

dient of 14%. The main levels consist of a

series of parallel drives that are

Education Under Ground Mining E Book 02

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Transcript of Education Under Ground Mining E Book 02