Title of Presentation

Report
Research Update
Automated Bolting
and Meshing Project
Project Outline
Summary of the Project
•
This project aims to help contribute to ACARP and the Australian’s
underground coal industry’s CM2010 initiative in achieving production rates
from a continuous miner of at least 10 metres per operating hour and 20 hours
per day utilisation by 2010.
•
We aim to do this by developing a system integrated into a continuous miner
platform that will fully automate the process of self loading and installing:
1. rib and roof SDB bolts, and associated plates, washers etc.,
2. steel roof and rib mesh or other alternative roof confinement material,
3. materials handling systems needed to efficiently supply consumables at
the expected rates of use.
Today
ACARP Funded
Project C17018
Direct Industry
Funded Pilot Study
2007 / 08
2008
2009
2010
Project Outcomes
The expected major benefits of this project will be:
•
an overall decrease in roof and rib support installation cycle times that will directly
increase roadway development production rates;
•
the reduced exposure of personnel to unsupported roof, dust, noise, water, moving
equipment and outburst conditions.
–
For LTI frequency of hand/finger injuries by employer activity, roof/rib bolting had the
highest incidence at 26% followed by materials handling at 16%. For injuries causing
death, there have been 107 fatalities for NSW coal mine in the past 25 years with 61%
occurring at the development face and 57% related to rock falls;
•
reduced manual handling injuries by improving the logistics and storage method for
the loading and transportation of roof support consumables to and then within the
development area and finally onto a continuous miner.
•
the removal of remedial and repetitive manual tasks that allows for better utilisation
of mine operators elsewhere in the production process.
Project Outcomes
To date:
•
Preliminary study (Aug 07 – March 08) to identify technical risk, likely hood of
success and to formulate preliminary concepts for industry consideration.
Colliery
Company
Location
Entry
Miners
Observed
Strata
Condition
Dendrobium
BHP Billiton
Mt Kembla, NSW
highwall
ABM20
moderate
West Cliff
BHP Billiton
Appin, NSW
trolley car
12CM30
moderate
with gas
Appin West
BHP Billiton
Douglas Park, NSW
shaft & cage
12CM12
moderate with
very high gas
Beltana
XStrata
Hunter Valley, NSW
highwall
12CM12
very good
Austar
Yancoal
Cessnock, NSW
trolley car
ABM20
ABM25
very poor
Angus Place
Centennial
Lithgow, NSW
trolley car
12CM30
poor
Springvale
Centennial
Lithgow, NSW
drift
12CM30
poor
Crinum
BMA
Emerald, QL
highwall
ABM25
12CM12
very good
Grasstree
Anglo Coal
Capcoal
Middlemount, QL
shaft & cage
12CM32
good to very good
North Goonyella
Peabody
Nth Goonyella, QL
drift
ABM25
ABM20
good
Northern Underground
XStrata
Newlands, QL
highwall
12CM12
very good
Major Observations
• Although roadway development when simply broken down is “cut, bolt, convey”, there is
an amazing amount of variance in the process that makes it difficult to automate.
Physical Variance
• Geotechnical conditions
• Machinery preferences
• Bolt pattern density
• Cutting cycles
• Seam height
• Logistics
Intangible Variance
• Work force culture
• Management standards
“variation is Automation’s worst enemy”
Can Lean Automation be the solution for bolt
and mesh handling?
Lean Automation
•
In general terms, Lean Automation is an alternative to rigid and inflexible
dedicated automation machinery with light weight multipurpose
reconfigurable flexible robotics.
•
This flexibility allows them to be used for multipurpose operations (like bolt,
plate, washer and mesh handling) by using multitasking end effectors.
Managing Variance in Automation
•
Difficult to make a ‘one-fits-all’ automation device that will load bolts, plates,
washers and mesh.
•
Lean Automation provides the needed flexibility at minimal capital costs,
while maintaining the typical automation benefits of increased control and
efficiency.
•
Also allows for easy reconfiguration for various CM machine layouts and
different mine roadway dimensions.
Reprogrammable manipulators
Intelligent sensing
Managing Variance in Automation
Managing Variance in Automation
Industrial Manipulators
Multifunctional end effector
Mesh dispensing unit
Two cooperating robots with
additional linear motion
Bolt, nut and plate presenter
Mesh Handling
Mesh Handling
Delmia V5.
Future Automation Tools
Logic control integration
3D CAD integration
DASSAULT SYSTEMS
V5.
Computer Aided Three
Dimensional Interactive
Application (CATIA)
Abaqus suite of FEA
and CFD
Product Lifecycle
Management (PLM)
Digital manufacturing
and robot interfacing
RD Simulation
RD Process
RD Simulation
CSIRO Mine Mapping
Where to from here
Year one
• Determine how the SDB will be combined onto a continuous miner.
• Building a prototype materials supply delivery system for bolts, plates,
washers etc. in the laboratory and demonstrating the automatic
loading of SDB into mock up drilling rigs.
Year two
• Building a prototype materials supply delivery system for mesh and
demonstrating the automatic placement of the mesh into a fixing
position.
• Interact the bolt and mesh cycles together for fully automatic cycle.
• Design and simulate various configurations to suit the variation
outlined earlier.
• Determine and design a material supply chain to the machine at the
expected tonnage rates.

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