Mining Hoist Wire Rope Smart Inspection Expert System
The "China Coal Mine Safety Regulations"
stipulates that "the hoisting wire rope must be
inspected once a day." Each mine requires two
persons to conduct the inspection at the same
time. The speed of the winch is 0.3m/5 during
manual inspection, and then the rope is inspected
visually, hand touched, and knocked. If you
encounter any suspicious places, stop immediately
and use a wide clamp vernier caliper to measure.
When the surface of the rope body is covered
with heavy oil dirty, it needs to be cleaned before
the inspection can be performed, which greatly
extends the maintenance time. Take the YG
mine auxiliary shaft hoist as an example: the
main motor power of the winch is 800kw, and
the inspection time is about 40min once a day.
Only this item consumes 192,500kWh every
year.
- TCK.W
- Information
IOT+ 5G+ WIRE ROPE INTELLIGENT MONITORING PLATFORM
1、Mining Hoist Status Overview for Bayangale coal mine
The main hoist of Bayan Gaole mine is a 4-rope floor type friction hoist, whose height is 595 meters with lifting speed of 10.37 m/s in
the production process and lifting time of about 3 minutes.
The lifting amount of a full cycle is 38 tons times two. The motor power of the hoist is 5000kW·h, with 20 lift cycles per hour and 360
working days per year.
2、TCK. W system applications
1.Wire rope safety has been raised to the highest level
Realize the replacement of manual inspect with machine intelligent inspection. Complete 24 hours X 365 days wire rope full life cycle
safety monitoring. Wire rope safety hazards can be found in a timely manner and completely eliminated rope breakage accidents.
2.Complete the intelligent monitoring of big data at the same time of production, which is costs reduction and efficiency improvement.
2.1 According to the Coal Mine Safety Regulations, the lifting of wire ropes must be checked once a day.
2.2 The mine inspector inspects the wire rope once a day at a speed of 0.5m/s and takes 0.5h. One inspection needs energy consumption
of 2500Kw, which reduces 10 lift cycles namely 760 tons. The annual inspection time is about 180h, with energy consumption of 900,000 kW.h,
reducing 3600 lift cycles, namely 273.6 million tons. Based on the current price of 1760 CHY per ton of coal, the annual output value
will be reduced by 481.5 million CHY.
2.3 With TCK.W system, the mine can be realized with monitoring at the same time as production. The annual reduction of shutdown
time will be 180 hours, during which 273.6 million tons of raw coal can be increased , namely output value of nearly 481.5 million CHY.
2.4 Save 900,000 kW·h of power consumption special for wire rope inspection, and save electricity costs of 369,000 CHY.
3、Significant energy-saving and emission-reduction effects, helping to achieve the dual-carbon goal
The annual energy consumption used for rope inspection at the Bayangaole Mine, China is 900,000 kW.h, which has invisibly increased
carbon dioxide emissions by 897,300 kg. After using the TCK.W inspection system, it can save 900,000 kW.h of energy consumption for
rope testing and 897,300 kg of carbon dioxide emissions throughout the year, providing a strong technical guarantee for the realization
of the "Dual Carbon" goal.
4、Save the cost of rope and provide technical catch for protecting the environment.
The cost of use of rope in Bayangaole Mine, China is 1,722,100 CHY, and the rope replacement period is 2 years. The average annual
cost of ropes is 860,000 CHY, and there may be waste of wire ropes. According to the coal mine safety regulations, after 2 years of use,
the wire rope can continue to be used for 1 year if the number of broken wire rope, the rope diameter reduction, and the degree of corrosion
do not exceed the regulations. We believe that the TCK.W intelligent monitoring system may prolong the service life of wire ropes by at
least one year and reduce the cost of ropes by one third while ensuring safety. The annual cost of ropes can be reduced from 860,000
CHY to 570,000 CHY; the average cost of ropes each time is reduced by 860,000 CHY.
We believe that under the state of intelligent monitoring of the TCK.W equipment for the wire rope of the Bayangaole Mine, China, the
safety development trend of the wire rope can be fully mastered, and it is entirely possible to save the amount of wire rope and reduce
the cost of the rope under the premise of ensuring the safety of the wire rope. And this will contribute to perform President Xi Jinping's
solemn commitment to the “3060 dual-carbon target” put forward by the Chinese government at the United Nations Global Climate
Conference and for the circular economy, resource protection, and environmental protection.
