The main aim of the project is to develop solutions aiming at as large as possible decrease of bucket wheel excavators failure frequency during operation in difficult mining conditions including unmineable inclusions and geological structures with excessive mining resistance. It is planned that developed solutions will refer not only to operating bucket wheel excavators but also to newly constructed. It is necessary to elaborate new solutions because currently applying rules and regulations referring to excavators construction do not include sufficiently mining conditions occurring during exploitation of such structures.

The main aim of the project will be obtained by:
1.
Development of conditions to be laid down during construction of mining units in order to decrease dynamic loads during operation of buckets in structures with excessive resistance as well as decrease of impulse loads resulting from encountering of unmineable inclusions without decrease of operation efficiency and as much as possible adjustment of load carrying stricture of the machine to resulting from previous experiences dynamic loads during operation in such conditions.
2. Development of constant monitoring of effort degree (immediate and fatigue) of load carrying structure of bucket wheel excavator enabling proper control of machine operation as well as prevention of possible failures. The monitoring system will be installed on load carrying structure because possible failures in this area have the worst consequences.

WP 1

Optimal adaptation of currently exploited and new bucket-wheel excavators for mining of overburden including interlayers with excessive mining resistance and unmineable inclusions...

WP 2

Monitoring system of bucket wheel excavator load carrying structure efforts and method of diagnostic signals analysis for current assessment of threats of load carrying structure damages as well as constant control...

WP 3

Real-time mine-face inspection system, based on geophysical methods, capable to detect hard rock inclusions and geological formations which are difficult to be excavated by bucket-wheel excavators...

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WP-2

The main result of WP-2 will be a monitoring system of effort of load carrying structure of bucket wheel excavator. The monitoring system will be based on constant analysis of operation parameters of main elements of drive system in correlation with current level of stresses measured in important parts of machine construction. The system will constantly analyze diagnostic signals and will assess potential risk of load carrying structure failure resulting from temporary overloading during operation. It will also analyze the influence of overloading on fatigue strength of construction elements of load carrying structure. Reports generated by the system will deliver important information for equipment operator and will enable current reaction on occurring situation or will enable change of machine operation plans depending on expected mining resistance.
In order to achieve the foreseen aim it is necessary to conduct preparatory works including:
  1. Theoretical development of a method of load carrying structure efforts assessment on the basis of analysis of measurements registered and processed by the system.
  2. Realization of simulation tests and tests stands preparation enabling development of method of localization of measurement sensors in order to monitor selected areas of load carrying structure of bucket wheel excavators exposed to possible failures.
  3. Development of a method of experimental determination of parameters and indicators used for calculation of fatigue strength of structural elements on the basis of registered measurement signals.
System of analysis of structural elements efforts on the basis of constant monitoring of stresses and parameters of drive system of an excavator will enable decrease of excavators failures and will enable sustainable and rational management.