Predicting cutting performance

MINING research group CRC Mining has recently developed software that allows miners to analyse the cutting performance of cutting heads and drums before they are installed on shearers and continuous miners.
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Staff Reporter

Presenting a paper on the Cutting Head Performance Analysis Software (CPAS) at the 2006 Australian Mining Technology Conference, Bulent Tiryaki said the software is a prediction tool for pick forces, ranging arm forces, cutter motor power, and vibrations.

The new CPAS software was developed by rewriting the existing software of cutting drum performance analysis.

Cutting head analysis by CPAS is carried out by drawing the breakout pattern, predicting parameters, statistical analysis of reaction forces and total number of active picks in the cutting sector.

Tiryaki said the validity of the models for ranging arm forces, and cutter motor power in CPAS code were evaluated during underground trials at Beltana Mine.

“Actual values of cutter motor power, vertical reaction force, and vibrations were compared to those predicted by CPAS,” he said.

“CPAS predictions and actual values for above parameters were of similar magnitudes, revealing the potential of CPAS in simulating shearer performance in coal seams with small amount of cleating and abutment loads.”

“However, further underground trials are needed to establish respective relationships between cutting power, ranging arm forces, vibrations, and the operational parameters of the shearer in order to validate/update CPAS model.”

CPAS is expected to provide assistance to mines in varying capacities. During the initial mine planning and equipment selection stage, CPAS can be used to predict the cutter drive power requirements and help with the selection of the shearer.

“Once the mine is operational, the software can be used to predict the effects of varying drum speed, haulage speed, and the web thickness on machine performance so as to arrive at the optimum set of operating conditions,” Tiryaki said.

“Determining fluctuations of reaction forces and drum torque for different pick lacing arrangements by CPAS will help achieve the optimum design for a given longwall face regardless of coal seam conditions.”

Tiryaki said the underground trials and computer analyses have proven the potential of CPAS model for predicting the cutter motor power and reaction forces for longwall shearers for Australian coal seams.

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