This paper studies both the thermal and mechanical behavior of brake system models in the case of the emergency braking of a mine hoist model. Using a step-by-step approach inspired by studies conducted on small brake systems with high rotation speeds specific to road and rail vehicles, a comparative analysis using a computer simulation was performed for the two types of brakes of a mine hoist system. A Solidworks model was built for two configurations: the drum-and-shoe and the disc-and-pads, and it was imported to COMSOL Multiphysics, where the material properties and simulation parameters were defined. Simulations were performed for each configuration, first using a Heat transfer module in the solids to investigate the frictional heat. The results showed the locations of the hot points on the disc and on the drum, with the surface temperature reaching 97 °C on the disc and 115 to 159 °C on the drum. Next, simulations using a Structural Mechanics module were run to obtain the stress and deformation induced by the heat generated during braking. The von Mises stress of the drum-and-shoe brake occurred on the external surface of the drum and had a value of 2 × 108 N/m2. For the disc-and-pad brake, the stress occurred towards the edges of the brake pad contact and was 4 × 108 N/m2. Both values were under the yield stress of the passive brake element material. Regarding the deformations, for the drum-and-shoe brake, it appeared towards the outer boundary of the drum, being 0.45 mm, and for the disc-and-pad brake, it was situated at the external edge of the disc, being 0.25 mm. COMSOL Multiphysics allowed the evaluation of the thermo-mechanical behavior using noninvasive techniques since actual emergency braking testing on a working mine hoisting installation is not possible because of safety and logistic concerns.
The sustainable exploitation of raw materials, with improved safety and increased productivity, is closely linked to the development of mechanical mining installations. Mine hoists are designed for the transport of material, equipment and personnel between the mine surface and the underground. The mine hoist braking system is of paramount importance in its safe operation. Thus, for both drum and disc brake systems, the temperature of the friction surfaces is important for ensuring efficient braking, as exceeding the temperature threshold causes a decrease in the braking capacity. In this paper we present a numerical calculation model for the temperature of the braking disc of a mine hoist in the case of emergency braking. A real-scale model was built, based on the cable drive wheel and disc brake system of a hoisting machine used in Romania. Real material characteristics were imposed for the brake discs, the cable drive wheel and the brake pads. The simulation was performed for decelerations of 3, 3.5, 4 and 4.5 m/s2. The analysis shows that regardless of the acceleration and time simulated, the disc temperature reaches its maximum after 1.35 s of emergency braking. This value does not exceed the 327 °C limit where, according to previous studies, the braking power starts to fade. It means that the emergency braking is safe for the acceleration and masses under consideration, in the case of the studied mine hoist.
For the ERc 1400-30/7 type bucket wheel excavator (BWE) used in various Romanian open pit mines, a virtual model of the boom was constructed in SolidWorks. On this model, the variable in time forces acting during the excavation process were simulated, and the time history analysis (time response) was performed. This dynamic time response analysis was performed for excavation of homogenous material only, considering the damping as being of Rayleigh’s type, where the damping matrix is a linear combination of the mass and stiffness matrices. Based on the conducted analysis, the displacements of the boom during excavation were observed.
The paper deals with the modal analysis and frequency response analysis of a bucket wheel excavator (BWE) boom, obtained by simulation, based on a virtual model of an existing BWE boom. The boom, which generally is realized as a spatial truss, is the most vulnerable subsystem of the BWE, being submitted to severe operational loads characterized by very pronounced cyclical, dynamic and stochastic variability. This vulnerability is the consequence of its shape and constructive parameters and the nature, source and character of the external exciting loads to which it is exposed. The classical approach recommended by standards and norms cannot predict the occurrence of failures caused by vibration, which produces fatigue due to the load’s cyclical variability and the deformation produced by resonant vibration of some constitutive elements. As exciting load we considered the operational forces acting on the bucket wheel. In this manner we can take into account the constructive features – with modal analysis, and the vibration regime – with frequency response analysis. The proposed method is useful both in the design phase of new load-bearing structures of truss type subjected to high-variability forces, and also in refurbishment or improvement phases of the existing structures of this kind.
Breakdown of stackers and excavators in opencast mines is possible because of operating, manufacturing and structural causes, and it produces high financial losses. These can be prevented by using various measures, including analyses and strength tests, with computerized modeling and simulation using FEA or other techniques being implemented in the recent years. In this paper a fatigue study is conducted on the boom of a BWE. Based on a computer model of the boom previously developed in SOLIDWORKS by our author team, first the modal analysis is conducted for three positions of the boom by studying the frequency response during the excavation process. This is followed by the time response determination corresponding to the maximum displacement frequency, in order to assess the stress during the excavation process, which causes the material fatigue in the boom structure. It was found that the maximum displacements appear when the BWE boom operates in a horizontal position. The aim was to estimate the period of time to failure in order to prevent unwanted accidents, and to develop a method that is applicable to any surface mining or industrial machine with similar structure.
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