ACARP ACARP ACARP ACARP
Open Cut

Hoist Control Project: Project Summary Economic Benefits of Hoist Control to Dragline Operation

Open Cut » Overburden Removal

Published: February 98Project Number: C5001

Get ReportAuthor: John Vazey | WBM

Field tests on the hoist drive of draglines have shown "overshoot" and oscillations of the drive gearbox torque during the lifting stage of the cycle. These dynamics, superimposed on the mean torque requirement, contribute to additional damage in the mechanical components of the dragline particularly in the hoist drive. The project investigated the implementation of feedback control on the hoist drive to reduce the torque overshoot and dynamics with a goal of increasing component life, or alternatively increasing suspended load for the same life.

The peak torque applied to the hoist drive occurs while accelerating the bucket. This torque is a sum of two effects, one accelerating the bucket and the other associated with a dynamic ringing of the hoist drive. A model of the hoist system was developed to simulate and trial various control strategies and determine their effect. The model was validated with field experimental measurements of electrical and physical parameters. The results of the simulations indicate that the peak torque during hoist can be reduced by 10 - 20% below present levels.

An economic analysis of the cost reductions through the implementation of improved hoist control indicates a potentially significant saving in maintenance costs. The reduction in peak torque should result in a tripling of gear life. The increase in the life of the gearing and other components has the potential to save dragline owners $250,000 annually through reduced maintenance. A full feedback control strategy would require a significant research and development effort in order to minimise the risk to large powerful machinery. A less risky alternative would be a system using improved precompensation of the operator input. The precompensation would reduce most torque overshoot by 20 - 40% and utilises components which are already a part of the hoist control network. Further research to develop and implement an improved hoist control system is recommended.

The economic analysis model was also used to review productivity advantages through increases in the suspended load. Hoist control was found to reduce the damage inflicted on machines through increases in suspended loads above the rated suspended load. The model showed that it was cost effective to improve the control system and increase the suspended load despite large increases in maintenance cost.

The extensive documentation of the modelling work carried out by WBM makes this report a vital key in further development of dragline control systems, and economic productivity analyses.

Underground

Health and safety, productivity and environment initiatives.

Underground

Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C19024Establishing Ecologically Sustainable Mine Water Release Criteria In Seasonally Flowing Streams

Extreme rainfall conditions in the Fitzroy Catchment over an approxi...

C25030Coal Mine Open Pit Final Void Closure And Relinquishment - Addressing Uncertainty In Coal Mine Environmental Planning

This report addresses uncertainties faced by coal mine operators whe...

C27046Estimation Of True Deformation Vector From Slope Radar Monitoring

Slope deformation radar monitors are now widely used in open cut coa...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27004Improving Coal Flotation With Oscillatory Air Supply

This report provides detailed information on coal flotation with os...

C25018Improving Solids Recovery And Moisture Reduction In Ultrafine Coal Dewatering

This report provides detailed information on fine coal dewatering in...

C27028Lab Froth Flotation Testing Guide With Coal Quality

Correct outcomes from laboratory froth flotation testing in coal bor...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26039Nanoporosity In Cokes: Their Origin, Control And Influence On CO2 Reactivity

This project using the outcomes of previous project C24060, examine...

C28063A Comprehensive Technical Review Of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies For Power Generation

Research and development has been undertaken worldwide to realise co...

C28064Carbon Structure Transformation During Coking Of Australian Coking Coals: Better Understanding The Coke Formation

Carbon structures of coke that are formed during the plastic layer a...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C28076Selective Absorption Of Methane By Ionic Liquids (SAMIL) - Phase 2 Demonstration In A Packed Bed Reactor

An alternative approach to high temperature oxidation of ventilation...

C26004CFD Modelling Of Reverse Thermal Oxidisers For VAM Abatement - CFD Modelling Of Fixed-Bed RTO Devices

The project is part of a larger multi‐phase program of study a...

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community

NERDDC

National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook

NERDDC